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Thread: Plug wire question

  1. 11-06-2007, 06:18 AM #1
    sawjo
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    Plug wire question

    I need to splice a couple of inches to the end of a plug wire because the end is chewed up. I can't replace the entire wire because its epoxied into the coil side. Any techniques or tips for splicing, or will it even work? I am using like sized ignition wire for the splice not regular hook up wire.
    Thanks in advance.
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  2. 11-06-2007, 07:48 AM #2
    Lakeside53
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    Most HT wire screws into the coil... joining HT wire generally doesn't work.

    What saw?
    Any sufficiently advanced technology is indistinguishable from magic."
    --Arthur C. Clarke,
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  3. 11-06-2007, 07:49 AM #3
    Gumnuts
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    Adding that bit.

    SHRINK WRAP
    Just one method i've used thats worked is to clean cut where you need to
    on the damaged end( slide shrink wrap on ,out off way).Naturally measure the piece you wish to add.Strip off one side, say 10 mm .Slit other side open the casing 10 mm ,enough to overlay with the bared wire ,and slide shrink wrap over and apply heat.

    Has'nt given away on me YET-

    Auto shop - .20cents !!!
    Last edited by Gumnuts; 11-06-2007 at 07:57 AM.
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  4. 11-06-2007, 07:53 AM #4
    cuttinscott
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    Quote Originally Posted by Lakeside53 View Post
    Most HT wire screws into the coil... joining HT wire generally doesn't work.

    What saw?
    I Believe he is working with a SEM ignition that the HT lead is molded into the coil

    Scott
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  5. 11-06-2007, 09:02 AM #5
    sawjo
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    Scott guessed it. Its a SEM ignition for a Dolmar 120, I have turned this saw into a "I won't be defeated" project . Thats a great idea Gumnuts, had'nt thought of that. I was going to solder a butt joint and then try to build up the void with electrical tape and shrink wrap - but I like the side slice and mate idea better. Thanks guys!
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  6. 11-06-2007, 09:10 AM #6
    timberwolf
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    I have extended plug wires before on project saws where the stock plug wire would not reach the plug in a cut off head. I just soldered, siliconed over the joint and added a piece of shrink tubing once the silicone set. No problems.
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  7. 11-06-2007, 09:13 AM #7
    scottr
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    But me no buts

    Quote Originally Posted by sawjo View Post
    Scott guessed it. Its a SEM ignition for a Dolmar 120, I have turned this saw into a "I won't be defeated" project . Thats a great idea Gumnuts, had'nt thought of that. I was going to solder a butt joint and then try to build up the void with electrical tape and shrink wrap - but I like the side slice and mate idea better. Thanks guys!
    Sawjo , if you can solder then you can fix it . Just strip off 1/4" of insulation on both wires , tin them then lap them side by side and solder them together . Insulate them with liquid lectric tape and if you want it to be purdy put some heat shrink tubing over it and heat .
    Scott
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  8. 11-06-2007, 12:41 PM #8
    Scooterbum
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    If you don't have a soldering pen,just take a needle or small finish nail insert it half into each cable in the center then silicone and shrinkwrap.
    I did not send this from my Goofy Phone Thingie !!!



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  9. 11-06-2007, 09:28 PM #9
    RaisedByWolves
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    Quote Originally Posted by timberwolf View Post
    I have extended plug wires before on project saws where the stock plug wire would not reach the plug in a cut off head. I just soldered, siliconed over the joint and added a piece of shrink tubing once the silicone set. No problems.


    You probably know this, but regular Silicone will corrode most electrical connections.


    .
    AAAaaaaaaaaaaa-Ah!





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    Last edited by livewire : Today at 02:09 AM.
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  • 11-06-2007, 10:10 PM #10
    gatkeper1
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    I have done it using Scotch 130C splicing tape and then covering it with a shrink wrap
    Greg

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  • 11-06-2007, 10:54 PM #11
    cuttinscott
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    ngk does make a high tension lead splice available through sled and bike shops but i do not think this app has the room.

    Scott
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  • 11-06-2007, 11:22 PM #12
    Lakeside53
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    Quote Originally Posted by RaisedByWolves View Post
    You probably know this, but regular Silicone will corrode most electrical connections.


    .
    yep.. most have either acetic acid or ammonia base...
    Any sufficiently advanced technology is indistinguishable from magic."
    --Arthur C. Clarke,
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  • 11-07-2007, 08:00 AM #13
    romeo
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    Most times, you can break through the epoxy and you will find that the cable is screwed into the coil. Sometimes you break the coil trying. I have seen the wire joiners work (the wire screws in from both sides) but like Scott said, you need the room.

    http://www.youtube.com/watch?v=bEM9lKZznhI
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  • 11-07-2007, 08:19 AM #14
    GASoline71
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    Quote Originally Posted by cuttinscott View Post
    ngk does make a high tension lead splice available through sled and bike shops but i do not think this app has the room.

    Scott
    Scott, are you sayin that there is no room because the splice will have to be at the point where the plug wire bends sharply, and usually comes out of the outer cover?

    Gary
    "Until it is demonstrated, one forgets the really great difference between the merely competent amateur and the very expert professional." Linus van Pelt (Peanuts)



    LMAO...
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  • 11-07-2007, 08:55 AM #15
    sawjo
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    What I did was expose about 5mm of each wire and butt soldered them together and built up the void with liquid electrical tape. I am letting this dry and then I will cover the joint with heat shrink. The soldered connection is good and strong and the joint will be covered by the SP boot. I am hoping this will suffice - I will let you know on spark quality, if I still have one! LOL.
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