Hey,if I posted this already I can't find it-tell me again! I've got a new set of plug wires I need to cut to length and put on the HEI distributor ends. They're resistor wires so there's kind of a two layer insulation covering the sensitive core. I need advice on cutting them to length. They are 8mm wires-I've experimented and found if I use the 14 gauge hole on my wire stripper,I can get pretty close with really nicking the core,but i want to be sure on the final cut. Any suggestions on how to do this properly without spending $75 on a special too will be welcomed,thanks.
Don't use your wire stripper--cut each layer with a sharp razor till you get to the core wire (the white insulator needs to come as well as the rubber exterior)...or, use a pencil sharpener. You need to leave enough wire (usually 3/8") to fold back over and crimp beneath the HEI ends. Did your wire set come with a vise-mount crimping die?
I've been doing this for years using a set of strippers that I bought at Sears back in my teens. It has provisions for stripping 7mm and 8mm plug wires, and also for crimping the ends. (The vise-mount crimpers that some wire sets come with are okay for the job as well...but I've had excellent results using my cheap Craftsman stripper/crimper...and it's a lot more portable than a bench vise...easier to work right at the car or motor!) In a pinch, I've used different universal stripping & crimping tools with great results...it's all in your touch more so than the tools you use. As far as automotive tasks go...sizing and fitting new plug wires is one of my favorite things! Oh yeah...while I got your attention, here's a little tip that will save you lots of grief when cutting and fitting your wires. You'll need to slip the boot over the wire before you put the metal end on it, so what I like to do is first cut the wire at a sharp angle rather than straight, at a point near the uncut end. This will give you an angled "point" to feed through the hole in the boot rather than a blunt wire end. Use a little silicone spray on the wire end and it will pop right through the hole in the boot and slide up and out of your way until you cut, strip and crimp your end...then you just slide the boot back down into place. Works great!
I use a box cutter. you just have to be carefull how deep you cut. I kind of roll the wire across the blade cutting it about 3/4 the way through to the center an pull off the insulation works for me. Carlg
i use one of the mini crimpers from msd - always found it works well. http://www.jegs.com/webapp/wcs/stores/servlet/product_10001_10002_747777_-1_10787
Spend the money on the special tool from MSD. They aren't too expensive. I think Snap-on also carries them now, and again, I don't think they're horribly expensive. I just bought one off the Snap-on truck to crimp on electrical fittings, and it's the same tool, with different (removable) jaws. It was not Snap-on brand, and was $35. Even if you go with the expensive one from MSD, they're worth every penny. You'll NEVER again buy universal one-size-fits-all wires...They make the job go VERY fast, they do an excellent job, and they make the final install look good. -Brad
I bought some HEI ends at Napa. You don't have to but the boot on first . Just crimp the end and insert into the 90 degree boot.
I have , and there are special wire cutters for ignition wires..makes the job a snap and they have the special crimpers too for the ends..25 minuet job on my V8
I've had high quality wires (MSD, Mallory, etc) that the terminals pulled off. I've ALWAYS just used a standard wire crimper/stripper for repairing them and when making new, custom lengths.....never have a problem when I've crimped it..... Special tools aren't always needed if you know how to do it.....unless ya just like buying tools......
I use a razor. I found that if you bend the wire right where you're cutting it - it's easy to control the depth. Once you get close it sorta just "opens" right up.
a good set of wire strippers has a stripper and crimper for the 8 and 7mm wires. if yours dont have them i would get another set that does. if you do this often its worth the $18 to buy a pair. if you only do this once its still pretty worth it.
Thanks. These are Accel wires,the metal end you crimp on came with the set and once crimped,just slides into the right angled rubber boots that fit on the distributor end-the plug end is already crimped. I bought the Accel vise based crimping tool from Amazon for like $5.50. I am not sure how far to cut -RF said "Don't use your wire stripper--cut each layer with a sharp razor till you get to the core wire (the white insulator needs to come as well as the rubber exterior).." There is a rubber like coating over the center wire, I thought I was supposed to leave this? If not, then what is what should the "ready to crimp" core supposed to look like? Copper, wire, what? Thanks.
No...cut down 'to' the wire. You want @ 1/2" of wire sticking out, then it gets folded over and the end gets crimped. Before cutting, I use WD-40 and slide the boot on, depending on the ends (90*, etc), then do my cut and crimp.
The core wire will have a small spiral wrap around it. If you don't fold it back and crimp under the end, you won't have any conductivity (no spark).
different wire brands have different looking conductors. I use the razor blade method, $6 for a box of a hundred.
For me, it was a time and frustration thing--Cut, fold, crimp, boot. Done with an end in about 40 seconds. Literally, about 40 seconds per end, if that. Perfect cut every time, perfect crimp every time. Every vintage car you ever have will need wires at least once. That's a lot of wires over a lifetime to get frustrated cutting with a razor blade, being overly careful not to nick the core, and hoping to get the crimp right with the vise-mounted whack-a-tool. But I will admit I'm a tool junky! -Brad
my tool box is full, and I built the shop around it so I can't get a bigger one, so no more tools for me.
jeg's has mallory spark plug wire pliers pretty cheap and they are really easy to use,harbor freight has them once in awhile on sale,i think i payed $12 for mine through jeg's ,if you get the pliers just compare the stripper hole size to the core of the wire,use vasoline or just alittle wd40 to slide rubber cap acouple inches over plug wire,wipe off,cut about half an inch of outer coating off,bend core over plug wire and use tool to crip the end,then just slide rubber cap over crimped end ,its really simple,doesnt take much time at all after you do one or two to get it down,LOL if you buy and use the pliers,you wont loan them out.
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