Hi everyone,

I've spent the last six months overhauling my '95 XJS 4.0. One of the repairs I have to make is to repair/rebuild the six ignition coil harnesses. The OE 20 gauge wire insulation is flaking off. I could buy six A/M connector pigtails for $32.00 to $64.00 each, OUCH! Last week I called Corsa Technic, LLC Motorsport Interconnect Products, Motorcycle Connectors, Sensors, through few exchanges they provided a quotation of $19.62 total for six assembles (pics below) for the 18 gauge wire I have. Preliminary try everything fits.

 

Keep us updated as you go along. I have intended to do this for a long time but just have not had the time

 

Will do. I have more parts being delivered tomorrow ( I messed up my first pigtail) that I ordered Friday. I have five pigtails complete and will finish up tomorrow afternoon. You must have the proper crimp tool to do this. I got my tool from Rostra Tool Co. in Connecticut 15-20 years ago. To get a proper crimp you need a quality tool engineered to meet the "pullout" force required. I am going to post pics of my pigtails and tool later today.

 

This is a picture of the Rostra auto crimp tool I used. Don't buy a cheap one! The wire pull out value is quite high so spend the loot$$ and get a good tool. Also in the pic is one of my pigtails. I'm quite pleased with what I did.

 

hmm. You are the first one that has recommended spending money on this tool. I bought a cheap one. I couldn't find enough evidence to prove that this was one of those tools to spend money on. So far so good.


"Pull Out Value" is not something I am familiar with (at least not since college ::wink:: ::wink:. What's the real world concern here and how does your tool ensure the proper "pull out value" is being achieved.


Thanks!

 

Back in the late '90s I worked for a connector manufacturer in Massachusetts. As part of a new product line being developed we needed hand tools to properly hand crimp contacts for field repairs. We worked closely with Rostra Tool Co. and they developed this tool for us (now you know where I got mine). You will notice the crimp force cam adjuster on the upper jaw to the right. "Pull out" is the force required to pull the wire out of a crimped contact. Wires don't pull out of crimped contacts with this tool properly adjusted (via the cam) - the wire will break before the crimp fails.

 

I did notice that, but there wasn't any numbers or info stamped in there, so I'm not sure I would know when, and by how much to adjust that adjuster.


I suspect that it would be superuseful when and if the cables and their connectors were in some kind of tension. There is no case, certainly not at the connections I am dealing with, where wires and their contacts would come under any sort of tension like that.


I think the cheap tool works for automotive purposes. It certainly is a nice tool to have, especially considering what you paid for it!!!

 

Perhaps this tool is a bit of "overkill" and I do appreciate the safety factor, but then again I can't beat the price.

 

I am so happy to have found these parts from this supplier. I measured the insulation and conductors on my 96 MY XPS and ordered 8 to have 2 practice sets:


2-Way Kit Sumitomo (DL090-2S-1) - DL 090 Sealed Series $3.27 $26.16
Socket/Wire Size:
1.25-2.0 mm˛ | 16-14 AWG (SUMI.B-SKT3)


Insulation/Seal size:
1.70-2.40 mm | .067-.094 in (SUMI-SL5)


Quantity Discount: $-0.16 $-1.28 Item Total: $3.11 $24.88