Bambalam

Thanks for the information Chris, yes the problem we face down under is the lack of supply's and suppliers - they only seem to have solid colors.
I have usually avoided the electrical issues in the past but you guys have inspired me - the injector and sensor looms have suffered from poor repairs and crumbling connectors - looking forward to tackling these problems now.

Simon

mb911

Trying to catch up on all this. Bought an 89 s4 that had a harness fire and now looking for sources.. if I had a sample I would be down for making my own.. any advice?

GregBBRD

It is certainly possible to build your own....although getting the proper wire, in the proper colors, in the correct sizes, with the proper outer sheathing might not be practical, in small quantities.
I'm making my harnesses completely different than either 928 Motorsports did or Sean does.
I'm very concerned about the correct, original look (with the correct red high temperature sheathing) and only interested in using the very best materials.
Additionally, I am using larger gauge main power wires on all the main red wires (to the alternator, to the ABS post, to the 14 pin connector, and to the starter) to help with "current problems", induced by resistance.
To compensate for the larger main power wires (which take up more room), I am now using TXL wire, instead of the lower grade GXL wire. Although the TXL wire is 4X the cost of GXL, the reduced outer diameter of the wire and quality difference makes it very worthwhile.
My looms come complete with all new mounting clamps and where necessary, new hardware.

Like everything I make, there is absolutely no compromise in quality.....something getting more and more rare, as vendors try to increase their profits at the "cost" of their clients.

dr bob

With a history of a harness fire, I suggest that you go for a good already-fab'd and tested replacement. That way there's a dozen or more fewer things to troubleshoot before you get to the original stuff left after the fire. Electrical 'fires' and melt-throughs in the KS-2 'front of engine' harness have a habit of collateral damage in the connected systems/components/wiring in the car. Greg's harnesses are not cheap, but they are absolutely top quality both materials and craftsmanship. I think Chris took on his own as a project for the fun and learning experience, and an excuse to get some cool tools to crimp and test. His "hydraulic crimper at work" correctly did about half a dozen critical wire ends just in the primary cables in that harness. Worth buying one? I have one I used on sailboat rigging that does a pretty good job. A $hundred for a hand version of that tool, another for the various small-terminals crimper, all the heat shrink and shielding, plus the time, effort and $$ you'll invest in modern marine (tinned) wiring, and the effort to assemble all that... Just buy a good one and sleep better.

GregBBRD

I think that the only other company that gets close to what I build is Kroon Wiring, but I doubt they are using upgraded main power wire.
Probably sticking to stock size (which has worked for many years, but as people add more power consumers, the wire size is commonly inadequate.)

Kiwi928S4

Hi Greg, is it possible to re-pin the OEM three pole plug for the oil pressure sender? Or do you have to rely on having sufficient tail on the existing wires to splice it on to a new loom? Mine is losing the insulation on the blue wires just as they enter the rubber plug - the copper is intact. I am reluctant to try pulling out the round pins to replace/re-crimp the ends? Sean talks about reusing the plug but it seems to be cast/molded over the pins?

Cheers

ken

GregBBRD

I heard that Kroon had remade that oil pressure connector, which would be great, for originality.
The 3 pin oil pressure sender was out of stock, at Porsche, a few years back, and I got in the habit of replacing the sender with the early style sender.
I still generally convert the harness to use the early style sender.