Today I started on the rear body harness

This is the fuse box that came out of the car...unfortunate

Fuel pump wires tied back with blue tape

I believe this a junction in the harness

What do you do with all these insulators? They are all rock hard. Do you just replace all the terminals??

@SteveJ

Edited January 15, 20232 yr by Patcon

Could you soak the harness? mineral spirits maybe? It'll soften up rubber.

1 hour ago, siteunseen said:

Could you soak the harness? mineral spirits maybe? It'll soften up rubber.

Hmmmm

3 hours ago, siteunseen said:

Could you soak the harness? mineral spirits maybe? It'll soften up rubber.

Maybe mineral oil instead of mineral spirits.

I've used mineral spirits to soften the rubber and wintergreen oil to keep the rubber soft. However, I just googled "rubber softener" and found that many are using silicone spray. Soak the rubber piece in silicone spray (it contains a plasticizer), seal it in a baggy for 3 - 7 days and voila, refreshed rubber. It's worth a try.

I have boiled parts in water with some wintergreen oil. I had so so results. Better but not super pliable.

I am open to ideas. It would be nice to find a way to soften up some of these pieces so I didn't have to replace them all.

 

There are lots of crimp splices in the rear body harness

Everywhere there is a crimp they wrapped it with a little yellow electrical tape

Harness all rewrapped with an extra green for the Euro tail light set up

As a side note the lamp harnesses have different plugs US to JDM. The JDM has a six wire plug with 5 wires in it.

If you want/need to replace the boots, here's a source: https://www.amazon.com/gp/product/B012T3YU2Y

I tried to work on clutch masters a while back. I got stumped because I couldn't get any of them apart. They were properly stuck.

Then I thought about using a grease gun but I had to figure out to connect it.

It turns out that Cody had a M10x1.0 grease zerk in his stuff

Then I had to trim off the bottom screw that retains the piston so I could close up the bottom hole but not trap the piston.

That's one hole closed but you have to block the reservoir hole too.

So we decided to tap it to M5x.8 and put a screw with a little teflon tape

You need to be really CAREFUL using pressurized grease!! You can get pin injected and that means getting filleted at the ER...

 

Edited January 16, 20232 yr by Patcon

10 minutes ago, SteveJ said:

If you want/need to replace the boots, here's a source: https://www.amazon.com/gp/product/B012T3YU2Y

What about the insulators on the barrel plugs, defroster, dome lamp?

For the bullets: https://www.amazon.com/gp/product/B073GM7WST/

Rings: https://www.amazon.com/gp/product/B08QHZXZ3S

Spade: https://www.amazon.com/gp/product/B07VKCCN12

36 minutes ago, SteveJ said:

For the bullets: https://www.amazon.com/gp/product/B073GM7WST/

Rings: https://www.amazon.com/gp/product/B08QHZXZ3S

Spade: https://www.amazon.com/gp/product/B07VKCCN12

Any concerns on quality? I found this guys site

http://cycleterminal.com/bullet-terminals.html

Seems to have a pretty good selection too

Do they sell the spades without the crimpers? I bought a set of crimpers a while back that your recommended then...