backnblack

I'm thinking it won't be long before I'm in need of one, mine is pretty crispy,keep me posted.
thanks Ben

davek9

Me too Ben, this could be a replacement item for this Spring's Manifold re-do.
Please keep up the good work!

928drvr86.5

Here is a picture of how the Driver's side is turning out.

Lizard928

Ben, where did you get those Ts etc?

928drvr86.5

The corrugated conduit, T fittings, Y fittings, and backshells for the injector connectors came from Harnessflex. This stuff is rated for 250F continuous, 300F peak temperature. I am also covering the injector and other sensor wires with fiberglass sheathing inside the conduit. So as a sensor's wires break away from the main harness and run to the associated sensor they will have additional protection provided by the fiberglass sheathing, the same stuff used on O2 sensor wires.

www.harnessflex.com

dr bob

Sweet!

Sad that the fine work is almost completely covered when installed. Comfort in knowing it's like that is priceless. Good stuff!!

928drvr86.5

The beauty lies in the fact that the conduit is split and the fittings are hinged so any section can be taken apart for troubleshooting or repair purposes should the need arise. As i continue tonight with construction i will take pictures of the the fiberglass sheathing before the conduit goes on.

dr bob

Ben, if you are adding fiberglass sleeve, can you take any advantage of the split in the loom? For heat and water resistance, I'm thinking the solid stuff might have an advantage.

Looks like I'll be making an S4 harness soon, if this is the "new" standard.

The_Remora

That is a great project!
I will be interested in an S4 injection harness.

backnblack

Ben do you have a ball park cost yet or is it to early to make that call, I'm just trying to set up my 08 budget and want to fit this in. If Dave K & Big Dave are looking at this maybe we could get a group buy save some shipping and all do it the same day at my house.
Regards
Matt

928drvr86.5

Right, the sleeving covers the wires so they are not acessible thru the slit in the conduit. If the backshell and pins are removed from the connector, the pins and wires can be threaded back thru the fiberglass sheathing. It's a little more difficult threading the pins and wires back into the sheathing but it absolutely can be done one wire/pin at a time. Alternately, you can just clip the pins, pull off the sheathing, repair wires etc, replace sheathing, and put on new pins. I have left enough room at the pigtails that the pins can be replaced a few times without the pigtail being too short to reach the sensor/injector. The Amp connector pins are readily available from a number of sources, I use Eagleday. Since the fiberglass sheathing is only between the T fitting and the end of the wires as they go into the connectors it shouldn't be a problem for the main body of the harness. I felt that the extra protection offered by the sheathing would offset the slightly more difficult repairs because of it.

The majority of failures in the 928 harnesses i have seen are where the injector pigtails make a tight bending radius to connect to the injectors, an area of high heat concentration apparently.

linderpat

depending on cost, I am interested too. Seems like a good WYAIT job when doing the intake refurbish, altho if the price is high and the existing harness isn't bad, then maybe not...that'll be my decision point...

928drvr86.5

Here are a few pictures of how i assembled the idle stabilizer connector using the fiberglass sheathing.

928drvr86.5

Matt,

When i started this project i had hoped to keep the price significantly below what the cost of an OEM replacement harness would be (~$1100). When i started to put a list of materials together and quickly added up the costs I realized that the material costs alone would surpass what i had originally hoped to sell a harness for. The majority of the cost from this project is coming from the DIN ( Porsche correct color coded) wires and the Amp Connectors in the engine bay.

As it stands right now there is a deletion of one size of conduit from my design and the addition of it's replacement size due to space constraints at the fuel rail on cyl 1-4. This will also necessitate a revision of the fittings associated with those conduits. So i guess it is probably too early yet for an assessment of what the cost is going to be. I can say that i am still aiming to be at a point less than the OEM harness; by how much, i don't know.

kaptnknemo

Are you paying retail for AMP connectors? If so, please send me a list of which connectors and pins you're using and let me see what price I can get from an AMP insider I know.

KK