Wire Harness reliability

With the demanding environments that wiring systems go though in the motorsports world, reliability is on the top of the list of requirements for any sort of interconnect system. Inconsistent and failing wiring means missed seat time, inconsistent performance, and even catastrophic failure if the situation is extreme enough.

The material used in harnesses has a major effect on reliability, automotive grade wire is good, with most qualities sufficient enough for most street cars. But using a higher quality Mil-Spec wire, leads to better abrasion, heat and voltage resistance- resulting in a longer lasting harness.

Chafe protection is a main point that is often forgotten about, bare wires with no physical barrier leads to damaged insulation and shorted conductors, and harness failure. Using proper measures equal to the relative stressors in the area will lead to a harness with a longer life span.

Mounting and routing is also very important, route branches too close to heat or mechanical dangers, and wear will increase or become immediate in the right conditions. Try to route your wires in an efficient manner avoiding dangers that can cause future problems.

Using proper tooling and parts when creating a harness or performing repairs is important as well, improper crimps mechanically can fail, and the lack of moisture protection can lead to corroded conductors and connections over time that can lead to increased resistance or just a mechanical break.

Keep these things in mind when doing your own work on your projects!