Course Tools and Materials

Below you will find the details to source the tools and materials we use throughout the course, everything is kept in the first post, but if you have any questions, or if any of the links break, shoot in a reply and we'll get it sorted :-).

Tools:

Sargent 3187 / GM12085271

Mechanical advantage and stiff jaws make it ideal for brass open barrel splice crimps.

Where I bought mine?

https://amzn.to/3t7K8hV

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Universal 16-30AWG Connector Terminal Open Barrel Crimp Tool

Good feel so you can apply as much, or as little pressure as you need, particularly on the second crimp stage on the wire insulation. My most often used crimp tool for connector terminals, in particular does a fantastic job on AMP Superseal 1.0 connector pins.

Where I bought mine?

https://www.milspecwiring.com/16-30-AWG-OPEN-BARREL-CRIMP-TOOL_p_405.html

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Tool-Aid Master Terminal Service Kit

Includes the three sizes of closed barrel crimp tool for use with Deutsch DTP, DT and DTM connectors, these are a great connector that you’ll use a lot. Also includes two open barrel crimp tools. The red handled ones have similar size dies to the Sargent 3187, and don't get used often. The blue handled ones have die sizes that are perfect for weatherpack terminals, bosch injector connector terminals, and most other terminals that include an integrated wire seal.

Where I bought mine?

https://amzn.to/3ojLYbO

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Universal / Metripack Crimp Tool

This is the same blue handled tool included in the Tool-Aid master terminal service kit, but just by itself.

https://www.delcity.net/store/Metri!Pack-&-Weather-Pack-Tools/p_804412.h_804413

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Ideal Stripmaster 45-097

Really robust and reliable. Larger frame than their stripmaster lite range, but also much more affordable. The only reasonably priced wire stripper I’ve found that will reliably and safely strip small 26AWG wire.

Where I bought mine?

https://amzn.to/3qUn7gb

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DEWALT D26962K Heatgun

Cheapest heat gun I’ve found with a settable temperature. The included case and nozzle attachments are a good touch too.

Where I bought mine?

https://amzn.to/3pnOKhx

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Materials:

Open Barrel Splices

1500 CMA and less of combined wire area: TE 62759-1

1500 to 5000 CMA of combined wire area: TE 63130-2

5000 to 10000 CMA of combined wire area: TE 62357-1

Best price and easiest company I have found to deal with for purchasing these is www.element14.com. Putting those part number into the search bar will get you to the right pages. Element14 has different pages depending on where in the world you are, in the US for example its called Newark, so it will be best to search for those part numbers from your location.

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Raychem SCL

Rigid shrinkable tube with a black potting compound inner wall. Excellent for harness branch sealing and support, and splice insulation. Most common sizes I use (the sizes specified are before shrinking) are 6mm (¼”) and 10mm (⅜”). Important to note is this heat shrink cannot be rolled onto a reel, and is generally only available in 1.2m (4’) straight lengths. I usually cut it up into more manageable sections for storage, as it’s only ever used for sealing and support, not a complete harness sheath. As above, I purchase this from Element14, and it will be best if you put the part numbers into their search bar at your location

6mm (¼”): SCL-1/4-STK

10mm (⅜”): SCL-3/8-STK

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AMP Superseal 1.0 Connectors

Once again, you can also find these on Element14. The connector bodies are available in 26 and 34 pin options. Important to note is that for each pin number option, there are multiple key-way options, and you will need to confirm that the keying is right for the device you want to connect to. I’ve given the part numbers for the most common connector bodies I strike, but confirm the keying here: http://www.te.com/usa-en/product-CAT-SU763-CH8172.html?q=&type=products&samples=N

26 Way connector body: 3-1437290-7

34 Way connector body: 4-1437290-0

Contact for use with 16-18AWG wire: 3-1447221-3

Contact for use with 20-22AWG wire: 3-1447221-4

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TXL Wire

I purchase my TXL wire from Waytek Wire, as their shipping options to New Zealand were the best I could find. Outside of New Zealand I couldn’t guarantee this, so it may pay to shop around. A google search of ‘TXL wire’ will net you a few options.

https://www.waytekwire.com/products/1454/Automotive-Cross-Link-Wire/&Insulation=Extra-Thin-Wall-Insulated

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General

A small list of the most useful wiring supply websites I use frequently, check our Community Wiring Accessory and Suppliers thread for more great links too.

http://www.msel.co.nz/

https://racespeconline.com/

http://www.milspecwiring.com/

https://www.waytekwire.com/

http://www.element14.com/

http://cycleterminal.com/

Brilliant - this is exactly the kind of stuff that was missing from the first version of the course, so thank you for adding this all in Zac!

This is great! Thank you

Hi Zac,

I can't find in the list just the blue crimper. Could you post were to find it, the one that you use in the course for the metri pack connectors, the one to close the seals?

Thank you.

I got one from here, I have't received it yet but from the pics look the same

http://www.cycleterminal.com/crimp-tools.html

scroll down to Metri-Pack Crimp Tool

Corex123 - I've added an amazon link for the tool itself to the original post :-).

https://www.amazon.com/Crimp-Tool-Weather-Metri-Pack-Quantity/dp/B00H9L1HEG

Great work on the fundamentals course Zac. I’m looking forward to ur advanced wiring course.

Mom the meantime I’m slowly starting to procure the materials and tools to do a semi ‘mil-spec’ loom and I’m wondering wether to go for multi coloured tefzel wire, or just a 2 or 3 colours for everything (ie different colours for different sizes of wire).

During my eBay searching I saw these little coloured ferrules which might do the trick fine. Have you seen these? I can’t find where to get them.

G'day Matt, long time!

I've seen them before, but have never used them, so not sure where to get them from unfortunately. I find I stick to a pretty simple colouring scheme:

Red for +12V Power

Black for Power Ground

Orange for Sensor Supply

Green for Sensor Ground

White for everything else.

This does lead to a lot of white wires that need to be terminated at the ECU header, but in reality it really doesn't take long using a multimeter to find the wire you're after and pin it into the connector. Saves a heap of money on different colours of wire!

The "Universal 16-30AWG Connector Terminal Open Barrel Crimp Tool" is a Sargent Tools 1026 CT. It looks like a decent all round crimper compared to some of the ones I bought previously off eBay.

For friends in the UK I picked mine up off Mouser (624-1026CT) for £28

Mouser also stock the open barrel splices:

- Terminals SPLICE 400-1300 Loose Piece (571-627591-LP)

- Terminals SPLICE 1970-4940 CMA Cut Strip of 100 (571-63130-2-CT)

- Terminals 4000-10000 025BR Cut Strip of 100 (571-62357-1-CT)

Also found the Sargent 3187 / GM12085271 from Waytek for a bit cheaper:

https://www.waytekwire.com/item/464/Sargent-3187-CT-Crimping-Tool/

Does anyone have UK equivalents of these tools or good site to get them.

Or link to some review of UK tools, I don't fancy paying extra for import because it add up pretty quickly in the end.

And I don't realy want to risk buying tools that will not perform as should.

Greg

Hey zac, I'm trying to get some wire from waytek, i can't set up an account as it seems you have to be in the us/ca or mex. how'd you get around this? they don't seem to best fast at email replies...

By the way awesome course! I'm looking forward to the advanced course, whats the eta on this?

Richard

Cheers Richard.

I dont rememeber having any issues setting up an account, or its possible I just checked out with a credit card, and never actually created an account? I used Youshop to freight forward the gear to me. It added to the cost, but was still cheaper than any other option I could find, and the wire is great quality.

Advanced motorsport course will be closer to the end of the year, however the club level / modified street car practical course should be out in the next month and a half or so! Working hard on it at the moment :-).

Cool thanks Zac! I’ll guve it a shot and see where I get to

Zac,

what's the name of the gold tape you use to hold the wires together before the step sheathing?

Hi Gerard,

It is called Kapton tape.

Cheers,

Theo

thank you theo!

Hi everybody,

I am looking for GEP relay and fuse holder and also the solid state relay from Zac's wibenar.

Any advise or link will be helpful

hi ZAC

from where have you purchased your Raychem heat shrink tubing ?

Thanks

Thank you all for the assistance to find the correct tools to make the job easy

G'day Aziz1qtr. www.msel.co.nz here in New Zealand is where I purchase DR25 from. IS Motorsport in the UK is another good supplier. You can usually find it on electronics supply sites like Element 14 and Digikey also.

Antonis, the GEP relay holder came from Waytek wire. A quick google will net you lots of suppliers of solid state relays. The Hella one I like to use (fits a standard relay holder) comes from a local automotive electrical store here in Christchurch, so that wont be much help for you, but there will be hundreds of suppliers globally for them too, they're pretty common.

Zac, Where did you get your log pick tool from? I cant seem to track one down. Cheers

Hi guys, I’m trying to find a 3M PL300 but it’s been a bit tricky to find one. Anyone with a link I can get one or similar? I’m located in Puerto Rico so I’ll need the company to ship it here. Thanks

Can I just confirm with you guys.

Is everyone using the Sargent 3817 crimpers to crimp the TE 4000 - 10000 62357-1 CMA Brass Open Barrel Crimps.

Is there a place to get non mil spec shielded cable? Im looking to gather some supplies to build my harness and I have found TXL wire from Ballenger Motorsports but I can't seem to find any TXL shielded wire. I know prowire has shielded but they only have mil spec (Tefzel).