Hi Jim,
When totally redoing my Healey in the mid 1980, one of the things I did wassend my harness out to be recovered with the proper weave rap. When itwas returned, many of the original ends were returned in a bag, as I hadrequested, and many were corroded. Thebullets had their wire inserted and folded over through the small whole in theend and were lodged in the appropruate connector. And that’s what I received.
When initially booking the harness rapping service, I questioned ifthey had a “Harness Diagram” (not a wiring schematic) that identifiedeach wire, connector, and where it was attached. Insecure withproviding this harness diagram, I finally got them to sell me a copy for all myharnesses and it proved a invaluable and a greate complement to my schematicduring installation.
When installing the harnesses, I made sure each appropriate connector(including each bullet) was soldered onto its designated wire and did not relieupon pressure to secure the connector. Where again appropriate, eachnon-bullet connector was further insulated with heat shrink tubing over thefull length of the receiving connector and extending over onto the wireinsullation. After cleaning and before inserting each connectoronto its receiver (including bullets into their connectors), Iliberally applied Dielectric Grease as the final electrical isolatorand to eliminate any vapor penetration/corrosion. Itshould be understood that Dielectric grease is not conductive butinsersion pressure will easily move the grease aside to expose a goodconnection. Over the years, I have hadoccasion to disconnect both bullet and non-bullet connectors and have not foundany that exhibit corrosion.
Most new harnesses are constructed with heavier gauge wire to carry the load ofmodern electrical additions. Although this improvement does provide a greatermargin of electrical safety, it also can cause more difficulty when fitting theharness into the car. Since my harnesses were, and still are, original,they were not as resistant to meeting the contours when placed. However, to deminish the original and newloads passing through original components and switches, I have supplimented myoriginal wiring with added harnesses constructed with heavier wire and relaysto allow my original components and finer wiring to carry the much loweramperage needed to switch and not operate. In this way, I have added such additions as Halogin head lights,alternator, sound system, etc., and have significantly lowered the level ofpower passing through my old original components and harnesses. Additionaly, these added supplimentalharnesses can actually be removed with components return to originality.
Last, consideradding additional fuses as part of your new harness installation. I chose to add in-line fuses as they areeasily hidden and can be easily installed to cover specific circuits and/orcomponents. How ever you choose to go,it is the perfect time to address adding protection to your electrical system.
Good luck andenjoy the task,
Ray(64BJ8P1)