Wiring electrical accessories...
Wiring electrical accessories and making repairs is not as complicated as trying to figure out how to wire an entire vehicle. A proper wire repair or the addition of a hardwired electrical accessory can last longer than factory work.
A few weeks ago I was four-wheeling with some friends and their old Jeeps when disaster nearly struck. An electrical fire started in the engine compartment of one of the CJs and fried a wiring harness. Once the smoke cleared, it was easy to find what happened: The wiring for the auxiliary lighting was haphazardly strung along a factory wiring loom on the firewall. A poorly covered splice in the wires chafed against a cheap metal wire clamp and shorted out. We were lucky we caught this in time-the Jeep could have burned to the ground.
I've run across some dangerously poor wiring jobs in my day, and it would have only taken minutes to do the job right. I bought two old Ford trucks and a Jeep Commando that were wired with residential electrical wire. What goes through someone's mind when he wires a vehicle like this? Automotive electrical wire is cheap, and it's relatively simple to properly splice together. When wiring is installed right, it will safely last for years.
After a good session of ribbing my buddy for his lousy wiring job, we strapped up the Jeep and towed it back to camp. His Jeeping was over for the weekend. Using the right tools and supplies to do the job correctly is extremely economical and worth the additional effort. Follow along as I explain some basic wire splicing and protection.
This is typically what happens...
This is typically what happens to a poor wiring job: The electrical tape eventually loses its grip and peels off. When the wire isn't properly secured and protected, flexible protective casing can be worn by chafing or torn away by moving mechanical parts. It was only a matter of time before this wire's protective sheathing was worn away.
My personal favorite solderless...
My personal favorite solderless wire connectors are these Extreme Condition connectors from Painless Performance. These high-quality connectors are covered in heat-shrink material that will not crack under high temperatures. A heat-activated adhesive waterproofs the connection, and they are vibration-proof and resistant to saltwater, battery acid, fuel, antifreeze, and diesel fuel.
Numerous products are available...
Numerous products are available like braided sleeving on the left, plastic sleeving on the right, and heat-shrink tubing that will easily and effectively protect electrical wiring. When running wire through critical areas like a firewall or around mechanical parts, rubber hose can also be sliced in half lengthwise and then zip-tied around the wire to protect it.
You would think electrical...
You would think electrical tape is easy to apply, wouldn't you? Day after day, I see tape installed wrong. If you must use it, firmly wrap the tape around the electrical wire and don't stretch it too tightly. Once you have three or four wraps around the wire, cut it with scissors. Don't pull it hard and tear it off. The tape in the second picture has been wrapped too tightly and torn off. When the tape heats up at extreme temperatures, it loses its stickiness and the tension from being overstretched will cause it to separate, eventually leading to exposed bare wire. Properly applied electrical tape will hold in place twice as long as tape that's not.
Strip wire with the right...
Strip wire with the right tool. This makes a clean and safe instillation. Improperly stripping wire usually damages its strands, which can lead to restricted current flow, minimizing the performance of electrical accessories and components.
Soldering wire connections...
Soldering wire connections is easy, makes a connection very strong, and gives the splice excellent conductivity due to the metal properties in the solder. Solder also slows or stops oxidation, and the connection is non-permanent. A soldered splice in two wire pieces can be reheated and removed or terminated.
Heat-shrink tubing is superior...
Heat-shrink tubing is superior to electrical tape and is my preference when covering a wire splice. A heat gun is well worth the investment and can cost from $15 to $30. Heat-shrink tubing is about $3 for a 3- to 4-foot length. On critical joints, I double up the heat-shrink.
Protective braided sleeving...
Protective braided sleeving is a great way to protect wire from chafing damage and makes an installation look clean and professional. Heat-shrink tubing makes superior closure at the end of the braided sleeving and will last much longer.
Properly securing electrical...
Properly securing electrical work is imperative, especially on a 4x4 that is run in harsh environments and conditions. I like these screw-on or bolt-on metal clamps with protective rubber lining which prevent wire chafing. These will last much longer than plastic clamps with adhesive backs and can be purchased at any electrical supply shop.