Concentric Twist - Insanely Overspec Wireharness Build on Classic 964
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- Опубликовано: 26 июл 2024
- Time to build the most overkill, overspec harness possible for my Porsche 964 track car! This all started out with me cutting the old factory harness into pieces at the beginning of this series, and now starting to finally put it back together.
This episode covers the concept of the very highest grade of motorsport harness design and fabrication including concentric twist, booting, refuel wiring and the engineering piece behind it.
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Videos recommended to watch:
Check out the rest of the my Porsche 964 rebuild (nearly 50) videos here ➤: • Porsche 964 Rebuild #p...
Check out the rest of the Porsche 911S Targa 1976 - Signature edition rebuild videos here ➤: • Porsche 911S Targa 197...
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Email me at ➤: 💌 info@islandworks.one
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Tools used in the episode:
The tool used for the design is called Zuken E3: www.zuken.com/en/product/e3se...
Wires used are Tefzel MIL-W-22759/32
Heat shrink Raychem DR25
Heat shrink boots from Raychem
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Special thanks to Arnaud from E3 for all the help!!
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Chapters and Key Moments:
0:00 - Introduction to Harness Building
1:10 - Introduction to Engineering the Harness with E3 Form Board Software
4:32 - Overview of E3 Software and Wire Routing
8:10 - Tools Preparation and Cable Cutting
10:03 - Initial Test and Twisting Cables
12:16 - Assembling the Core of the Harness
14:07 - Applying Heat Shrink for Testing
15:30 - Beginning the Real Harness Assembly
19:55 - Incorporating Zip Ties for Support
22:01 - Fitting the Harness in the Car and Routing
24:08 - Applying Heat Shrink to the Harness Sections
25:33 - Finalizing Heat Shrink Application
27:00 - Creating a T-Connection with Potting Compound
28:27 - Comparison between Old and New Harness Design
29:32 - Conclusion and Looking Forward to Next Steps
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#porscherestoration #porsche964 #islandworkssweden #HarnessDesign #AutomotiveWiring #CustomHarness #PorscheDIY #carelectronics #MotorsportWiring #HarnessAssembly #ConcentricTwist #PerformanceWiring #CarRestorationProject #PorscheModifications 
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Hey Jonas, once again I really admire your dedication to optimising every single component of this fantastic build, your desire to learn new skills along the way, and best of all, your generosity in sharing what you learn with us! Thank you brother, please keep at it!
Second thought on your form board. Having spent close to 20 years in aviation, a digital form board is great, but I have always found that physically laying out the harness for actual cable routing versus theoretical routing in the E3 software makes life significantly easier once you are actually building your main and sub-harnesses.
I started with running ropes between the components (last episode) and took the routing and actual lengths from there.
The CAD is then to design all the signal routing, splices, cable lengths and labeling.
Still first time around doing this for me…
@@islandworks Ahh I forgot you ran ropes!
Trick to remember, largest gauge wires to the center of the core. You shouldve used the 20AWG power in between the jacketed twisted pairs and moved two grounds onto the outer layer. You did pretty decent for a beginner and it takes a while to get the design and layup figured out right as it takes experience to move things around so that each layer uses the same gauge wire and also doesnt neccesitate a new layer
Awesome work, great tips
That's the most beautiful overkill i have seen in a long, long tome. Well done!! I can't imagine driving this piece of art you have created on a track, at least not a track with other people in their easily replaceable cars.
Beautiful job man.
Amazing work, love it!
Amazing episode, amazing harness, strong work.
thanks for making this video. I had heard about this wiring style only a few years ago.
Awesome. Took many HPA courses and made plenty wiring harness but none with the quality of yours. Once again, amazing craftmanship man. Looking forward to the next episode.
Awesome, well done!
Excellent! Good job
I've done a good bit of mil-spec connectors and wiring. I got great satisfaction watching your work come together. There is beautiful art in a good wiring job, and your work is art!
I love it! My favorite task that I don’t get enough time to play with!
Very interesting video. Well done. 👍
Great video. I loved the part in which you added "dead purple cables" to avoid loosing the round shape of main cable.
The last final touch 👍
I am still amazed at how high you put the standards for your build in every aspect of it and how you managed to do it all yourself. I am definitely gonna look into those courses if you recommend them
lovely work! thanks a lot!
Your skills and ingenuity is impressive! And taking your time to put these videos out as well. Great work Jonas!
Thanks!
Amazing job. Way back I built wiring harnesses using nails spaced in a board and waxed string for lacing. This was the old post office standard loom style.
This was a great video! I wanna try and build a harness like this for my car at some point.
Looks soo good by the way 👍
I enjoyed watching this! That tee was crazy to see take shape
Glad you enjoyed!
Nice work
Hello from France. Again and Again and Again great job. I like the new cable design
It took forever, but I like knowing what went into it for the future!
Amazing, did my own harness for my EFI/ECU conversion on my beetle, but this makes me want to go back and perfect it
Do it! Its perfect therapy!
Well done great video, I have been following the electric course from HP Academie find it very helpfull.
Thank for sharing .
Amazing work you've inspired me to try the twist method after a lot of reading
Go for it 💪🏼👍
Underbart!!
Kick Ass 💪💪 Nice Job
Nice!!
The added weight of the filler wire?! How did this make it in!!! Haha. Looks amazing Jonas!
Sir, my praises to you on this video. If this is your first time attempting this, i have to honestly say this is probably the absolute best most informative video for a beginner and intermediate wiring person interested in getting some insight onto what it takes to do these harness. I like you have gone over the HPA wiring courses, but i have also paid some fair bit of money for the Hands on MWC that EFI University does at their facility, which is a 3 day, hands on, course. My hat is off to you, really awesome work! And very detailed and informative! As we say in the industry, you practice until you dont make any mistakes. ;) Well done! Oh! and this is definitely NOT overspec'd this exactly what it takes when doing this kind of job!
Thanks for the feedback! It’s really a process and it was really my first of a concentric twist. What is difficult to explain is the huge amount of pre-work that goes into this before you start cutting wires…
Great channel and great job. As a residential electrician on over 1,000 houses I’ve been on disability for a long time. This really peaks my interest. My favorite part on residential work was always doing the breaker panel and meter loop. I bought one of the courses you mentioned earlier but never got around to taking it. I’ve been interested in cars and bikes far longer than anything else other than gunsmithing so it seems like a natural fit for a job I could do to earn some wages as well as enjoying the challenge. Perhaps I could also do it to help others out a bit at the same time. p.s. The versatility and ease of understanding of the software is a revelation. An extra thanks for that.
It’s a great subject and really fun to work on!
Your work is the most amazing I have ever seen
I am asking you so much
Could you please think of the next project in the same exact manner, but reducing weight for 955 Cayenne, which can do rally
That’s a great idea ;-)
Crazy
Nicely done man! You killed it, especially for your first one🤙🏼I wish my first one….or five….turned out as well as that🤣
Thanks! Lots of beginners luck and good camera angles ;-)
@@islandworks and you out in a lot of prior preparation by the sounds of it👌🏼I found that makes the biggest difference wether it comes out or now. I m loving the build, you attention to detail is admirable🤙🏼
@@rileylilwell5201 yes this was planned for quite a while! I still ended up redesigning it while building it due to some OCB that struck me!
thanks for all this helpful information, but I have one more question how can I determine the size of wires I need I know that we choose it according to the need and isolation and all that stuff but still confused between all sizes and types ?
As someone who is OCD, a perfectionist, and loves cable management... I couldn't take my eyes off this video. Love it!
Bra jobbat! Från kanndalen
Ett stenkast bort ;)
Wow, the software is super neat. Is it subscription based or its a one-time purchase?
Seems great for figuring out the splicing and layering the circuits of all components/sensors.
Boots should be heated slowly from the center. Stop with the edges incomplete. Then apply epoxy and finish heating the ends of the boot on. Good job though man.
That’s great input. Thanks!
Riktigt snyggt jobb! Jobbar själv på ett projekt med en wire harness. Använder också hi-temp silikon Kapton tape (Saint Gobain K201). Tefzel kablar och sen Glenair Amberstrand braid, sen connectors M83513 D-Sub’s. En del av kablarna är också Tensolite (otroligt bra kvalitet).
Snyggt! Kämpa på så blir det kanon till slut!
I also use cable ties, but I put them on backwards. Of course they do not permanently lock in place, but I do not need them to. The added benefit apart from being able to reuse them is that I do not need to snip them afterwards, thus introducing the risk of getting a nicked wire (ask me how I know this 😢).
That’s great input I’ll try that. What I’ve done is to tie them down and then use a cutter upside down and cut the head of the cable tie. This has worked safely so far.
@@islandworks I was absolutely sure I had not nicked a cable (actually I had nicked 2) and I had to rebuild the whole harness. Unfortunately just one mistake in a multi day process meant I had to do it again. Then again it is good therapy. Your build is my favourite in YT, keep up with the good work!
*Grabs 12v drill and snugs wires into the chuck*
Bzzzzzsssstttttr...
😂
Amazing stuff! How did you know how to adjust your individual wire lengths so that the harness with the twisted wires was the right length?
I didn’t really know. What I did was to add 15% and “then some”. It ended up with most of them being way too long and one wire being too short…
What kind of vise are you using to hold the harness?
Riktigt snyggt jobbat, kul att se. Smart det där med jordkablarna i dalarna på grundlagret.
Vilken del tycker du var svårast av allt? Ska snart ge mig på samma projekt för min Lotus..
Det svåraste är helt klart planeringen av hur man ska dra allt. Det finns så många sätt att göra det på och det blir lätt att man gör om det fler gånger. Ett program som E3 hjälper väldigt mycket!
Great video! Gotta question what’s the name of those vise ?
I’m not sure, found them online a long while ago.
Do you have a link for those vises??
You've done a really nice job! One thing for future - it is not ideal to use kapton tape every few inches to keep the outside layer together like you've done. The reason not to do this is it reduces flexibility and creates bunching at each spot where the tape is. It is preferable to use lacing cord in the opposite direction of your outer layer and wrap it tightly with this which will do the same job but allow the wires to slide against each other between joints. It's only a small detail but it will produce a better final product. Hope that helps.
Thanks for the input. I’ve been looking for this lacing cord but wasn’t able to find it. I’ll have another look once I do the next harness.
@@islandworks "Kevlar tråd", inte hittat det som köpts från Dupont men fiskelina i kevlartråd kan fungera.. Vart köpte du kablarna ifrån?
@@thevandor23 toppen! BJP till exempel för kablarna.
Where did you get the cables and heat shrink from? Looked all over for good quality ones in Sweden but no luck...
BJP has a good assortment of Tefzel and heat shrink. If you want to find it all I go to RS Components.
What is the yellow glue that you used on the wires that is hold to the core? And how can I get some?
It’s called Kepton tape. You can buy it usually where the wires are sold.
Absolutely a overkill, OCD.
By the way what type of ABS did you use, factory or aftermarket ? Also which episode was it ?
Aftermarket Bosch motorsport m4.
Covered in “pedal booster” and “stopping power”
It looks cool but is it the lightest possible harness?
I believe so. Any other better way?
@@islandworks I have absolutely no fucking clue, just wondering
Next step on the lightness scale would be even less cables. That would be possibly by investing a bit more in the components so they can distribute the input/outputs a bit more. Next car!
Hi fella, your marking an amazing job, I just don’t understand the exterior colours, each to there own, keep up the good work,
I had a color coding for which color did what like black is ground and white is sensor. In the end they are all the same and it's just there to to help while building it.
What kind of tape is that to secure the wires?
It’s called Kepton tape
@@islandworks Thank you for the information. Currently doing a harness myself and appreciate the video and knowledge sir
this is sdeff somthing i wanna do with my VR6 loom converting it to 97 OBD2 spec. but the looms are crude. and fragile!
Have you done it yet?
Imagine getting all the way done and realizing you missed 1 wire
Haha, that would not be fun.
You forgot to work out the weight saving!!!
That’s right! I’ll do a final tally one I have all harnesses complete!
I'm 3 minutes into the video and I want to recommend that you go watch Rob Dahm's videos as well as High Performance Academy's videos on concentric wiring and WHY it's important in motorsports grade wiring harnesses. Specifically, the crank and cam position sensors and their respective shieldings.
I’ve done both of them and they’re great! The HP Academy goes into all the depth and is a proper paid course though
Are the core wires used for anything (harness related) or are they just for support to allow the concentric twist to have something to rotate around?
Yes the core cables are usually larger cables. In my case it’s for the canbus network and for the Ethernet for the ECU.
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That's not how you start a concentric twist bud..there should only be 1 single wire in the center. That's why it didn't want to stay twisted
This works really well though :-)