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Custom spark plug wires

1.2K views 6 replies 4 participants last post by  Churchkey  
#1 ·
Assistance would be greatly appreciated ...

Picked up the Dyna Coils (DC2-1's) today. Ordered NGK race wires and semi-angled spark plug caps. Friggen wires didn't have anything on the end that will connect to the coil. The parts guy called NGK for verification and the only advice they had was to stop at NAPA and pick up some boots. Found some boots and connectors that snap perfectly into the dnya coils.

So .... Looking at the pictures, can anyone tell me the proper way to attach the connector to the wire? Should I strip any of the red housing or white insulation off? Should any wire be exposed inside the connector? Is soldering advised? It looks like it will be impossible to get the wire into this connector without shaving this down a bit - especially at the point where I put a blue arrow in the first picture. It's also fairly obvious that the point where the blue arrow is at is intended to be a bend point inside the angled boot.

I searched high and low on the internet and only found one vague DIY wire narrative that did strongly suggest using some dielectric grease when making your own wires to keep out air, dirt, grease, corrosion, etc. and to promote electric flow. Thoughts on that perhaps too?

Pic#1:[url="http://www.users.qwest.net/~warrior102/images/Wire_Pic_1.jpg>http://www.users.qwest.net/~warrior102/images/Wire_Pic_1.jpg
Pic#2:
 
#2 ·
You need to expose the center wire on the plug cable to get a proper connection. Just like when you strip back the rubber on any electrical wire to get a positive connection. Once you have the center wire exposed on the plug cable all you have to do is bend it back on the plug cable itself (outer orange plug cable on those NGK wires you have) and crimp the connector around the fat part of the outer cable making a solid connection with the connector and exposed center wire....don't forget to put the rubber boot on first.....I would use dielectrical grease before you slip the boot over the connector.....I would not solder....crimping should be plenty good.....
 
#3 ·
Suggest you route your wires, cut to length & take them to an independent auto repair shop & have the ends installed properly.

IF you like check my gallery PIX to see how I installed the Dyna's.
 
#5 ·
Thanks Guys! I'm fairly mechanical so I'll be off to get some crimpers and some dielectric grease.

Church,
Gallery pages were great for illustration and I'll be doing the same thing. Btw, your velocity stacks came yesterday too but they're sitting in the apartment office since I missed the UPS dude.

The first thing I did yesterday was figure out that my BAK plate layout wasn't arranged so I could enlarge the coil holes properly without needing to be in the same spot as the LCV. Pondered making a new BAK plate and then figured I'd just move the coils back to the frame where they started. Pulled out the 25 lb. box of parts that have been removed over time and luckily kept the plate and hardware for the coils. Church's pics reminded me I wanted to move the rectifier to the BAK plate now that the coils were out of there.

FYI, my DC2-1's came in an orange color as opposed to brown like most people seem to have gotten them in the past. Every time I look at em I'm thinking they look like they belong on a Harley. Doh!

Thanks again all. Gotta love this forum - I keep meeting Warrior owners who never heard of this website and wonder how they get along.