Spark Wire Crimp Location

Sorry if this is a "auto 101" question, but as everyone knows I'm just a photographer....

Anyway - I have the straight MSD boots and terminals to put on my new spark wires. Trying to get these the right length so that I can CNC the looms out of 16 gauge later on.

I understand with the 90 degree terminals that one should bend the conductor back and crimp with the insulation. But with these longer ones, do I crimp just the insulation, and then crimp the conductor in the part of the terminal that is just past the end of the insulation?

 

Dual-crimp terminals MSD spark plug wires instructions - Bing video

 

That link sends me to a Bing page that lists a bunch of videos and I watched almost every one of those before I posted and unless I missed one none of them seem to have the exact same straight/bend dual crimp terminals that I got at O’Reilly’s. I figured somebody on here might have done them

 

Tim's suggested video covers it. Your OP shows the dual crimp design terminal. Crimp at the conductor and then crimp at the jacket----as it lays in your second picture. Don't forget to have your boot on so you can slide it in place.

Plug Wires: Build Them Right

 

The gist is that you crimp the second location on the inner conductor. They show some fancy crimping pliers that I presume Jegs will be happy to provide .

I've only used the Summit wires, and they include a cheesy crimp tool with the wire kit. Maybe with the fancy MSD set they figure you can buy their crimp tool too?

 

Thanks for this. Not sure why I never found it while Googling before I made this thread.

I’ll be be using my electrical connector crimping tool and keeping my $13…

Anyway - does anyone recall there being a resource on this site where someone made a CAD file of the original Dauntless wire looms?

 

@Dave B - any pointers on how to slide these straight boots on the wire first? I went through the entire package of dielectric grease and unsuccessfully didn’t even get one on…

 

I used spray silicone, IIRC. Something I keep in the garage.

 

I use WD40

 

Warm the boot in hot, very soapy water and twist---like you were threading it on like a nut. Works sometimes!

Warm boot = expanded vs. contracted. For soap = dish soap, hair conditioner.

 

Thanks guys. I actually got it to work and finish the left-hand side by just putting on a load of dielectric grease inside with qtips, And taking a razor blade and chamfering the front rubber of the wire.

While I have everyone’s attention, on the right hand side - do the wires go above the valve cover and then to the spark plugs or between the valve cover and the alternator?

 

Over the valve cover.

 

It's not a CAD drawing but there is a picture and overall dimension in the Resources section of the forum.

Spark Plug Bars

 

Looking at this thread it seems to depend on the year: URL="Factory Engine Bay Photos?"]Factory

It looks like the earlier ones were over the valve cover while the later ones went around the front.

 

What are the tabs up on the top of the valve cover supposed to convey?

 

I’ll convert that to a DXF and cut some on the CNC tomorrow. Will share the file if successful. Do you think they are 16ga?

 

Yep, looks like 16ga:

 

Cheers thanks. I’m feeling like it might be time for me to start a “dumb engine question” thread since they are piling up in my mind….

 

Start an "Awesome Engine Question" thread instead.

 

Aerosol brake cleaner. Makes everything slippery as, well slippery. Then it disappears leaving no residue. Also great for sliding the left grip onto your motorcycle handlebar.