Bulkhead connector repair

[Frank D.]

Re: Bulkhead connector repair

Frank,

I badly damaged one pin. Will need to carefully remove and replace.

Dave K.

It happens, don't beat yourself up about it....if you follow the procedure I mentioned above it'll be as good as new, bending the tabs over and a bit of solder provides bot a mechanical connection and a chemical connection, so prob better than new.

[Dave K.]

Re: Bulkhead connector repair

Frank,
I will try but if I have to cut the pin I plan to add a short piece of wire to a connector into the new pin. This will keep all of the wire the same length.

Dave

[Frank D.]

Re: Bulkhead connector repair

Its your car but if its one of the high-current wires (thick red wire, etc) you are adding another point of failure; I'd avoid it if possible.

[Dave K.]

Re: Bulkhead connector repair

Frank,

It is not a high current wire.
Dave

[Ralph E.]

Re: Bulkhead connector repair

Dave, I don't know how you got an extra bulk head connector from LL.
A fews years back I broke the tab on my bulk head connector of my new wire harness and LL made me re-purchase the entire wire harness.
Lucky you!

[Dave K.]

Re: Bulkhead connector repair

Ralph,
They sell a repair kit for $120. Check their website. I bought mine from LL.

Dave K.

[Frank D.]

Re: Bulkhead connector repair

LL discourages this sort of repair and have warnings on their web site about it, but they DO sell the bulkhead repair kit and have for many years...
Prob some liability concerns about a novice burning their car to the ground from miswiring something - which I totally understand.

[Ralph E.]

Re: Bulkhead connector repair

Ralph,
They sell a repair kit for $120. Check their website. I bought mine from LL.

Dave K.

Dave, What I wanted was the little white connector from the engine harness to the bulk head connection on the firewall below the steering column.
That is what I thought you got. My mis-understanding.

[Dave K.]

Re: Bulkhead connector repair

Frank,

To get more wire slack, I will need to unwrap more of the plastic tape to lengthen the wires to reach their respective slots.

Regards,
Dave K.

[Frank D.]

[Dave K.]

Re: Bulkhead connector repair

Could anyone recommend how to get more individual wire slack in the harness? I intend to unravel more plastic electrical tape from the harness to loosen the individual wires. I called Lectric Limited and even though I have their harnesses in my car, they were non cooperative.

Regards,
Dave K.

[Frank D.]

Re: Bulkhead connector repair

I’m not sure how a wire wont reach now if it did before. At any rate, the way we did it on aircraft was to go back into the harness and add an extension piece. Eg using the same color and guage wire solder the extension to the original wire afre making a good mechanical connection first. Then insulate with two layers of shrinkable tubing. Then rewrap the wire bundle with electrical tape as factory.

No offense but there is a reason LL recommends agaonst most owners attempting this repair.

[Dave K.]

Re: Bulkhead connector repair

Frank,
I am having some difficulty getting the pins back into the slots. lack of wire slack does not help

[Frank D.]

Re: Bulkhead connector repair

It's awkward and confined working space and a tedious job.... If you review the photos in the link in the second post above you'll see I had what I consider to be adequate slack to migrate the wires to the new housing, so, if you have a stock or OEM-style harness I don't understand how you are running into this issue. Bear in mind, I'm a journeyman avionics technician and so such tasks were once my stock and trade.

[Dave K.]

Re: Bulkhead connector repair

Eagle Wire aftermarket harness.