CC HDS 2165 Electrical Harness Connector R/R

   / CC HDS 2165 Electrical Harness Connector R/R #11  

Richard001

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I like your choice of wire, individually timed strands is the best for this application.

The next important question, how do you plan on making the connections to the old harness wires ?

If the old harness wires a bright and shinny where you cut them back, then I recommend that you use non-insulated crimp terminals, then solder. If the wires are crappy looking, the just the crimp will do. Remember, use some shrink tubing with sealing adhesive in them. This will insure that the connections will not corrode in the future.

Here is one source:

If you have a Grainger store near by, this will work. other wise, see what you can find locally.

Richard
 
   / CC HDS 2165 Electrical Harness Connector R/R
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#12  
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woodsroad

woodsroad

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The next important question, how do you plan on making the connections to the old harness wires ?

https://www.amazon.com/gp/product/B08F3ZM6Z9/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

I've used these solder heat shrink butt connectors on my trailer, and they've held up well. I twist the two conductors together.

71ATVjjksEL._AC_SL1500_.jpg
 
   / CC HDS 2165 Electrical Harness Connector R/R
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woodsroad

woodsroad

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Woodsroad - Can you give us an update on your progress ?

Richard

The Rest of the Story:

I finally had some time to finish this job:

IMG_4362.JPG

Prep new wire: Strip, crimp and solder. Add heat shrink

IMG_4364.JPG

Insert spade connectors into the plug body.

IMG_4366.JPG

Some more heat shrink as a strain relief.

IMG_4367.JPG


IMG_4369.JPG

Splice the new plug assembly into the existing harness.

IMG_4372.JPG


IMG_4374.JPG

Add some 3/4" wide woven sleeving, with heat shrink on either end and...

IMG_4386.JPG


All done!

Thanks for your help, everyone!
 
   / CC HDS 2165 Electrical Harness Connector R/R #14  

Richard001

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Looks good.
I'm not sure that putting shrink tubing over the connector is a good idea. It's a great place for water to collect.

Did you clean the connector contacts on the switch ?

Richard
 
   / CC HDS 2165 Electrical Harness Connector R/R
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woodsroad

woodsroad

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Looks good.
I'm not sure that putting shrink tubing over the connector is a good idea. It's a great place for water to collect.

Did you clean the connector contacts on the switch ?

Richard
Richard, I'm going to put a piece of heat shrink around the back of the switch, overlapping the harness heat shrink.
The switch is getting replaced because the headlight position is iffy.
 
   / CC HDS 2165 Electrical Harness Connector R/R #16  

Richard001

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OK good to know.

I don't know if you have an Axe Man surplus store in your area or not, but I was at my local store a few weeks ago and I saw that they have a switch like yours with a fully populated connector and with about 8 inch flying leads for $7.

I don't have a clue if your local Axe Man would also have this.

Richard
 
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woodsroad

woodsroad

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Never heard of the place. Their retail stores are all in the Minneapolis area.
Neat stuff!
 
 
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