[Redroc]

My car has some worn wiring in the driver's door wiring harness that I need to repair. I'm in the process of pulling the entire wiring harness out of the door at the rubber accordian boot. Between the alarm, door locks, heated & power mirrors, 10-speaker stereo, and power windows this is not super easy. Anyways - I would like to repair the frayed portions of wiring with the appropriate colored wiring. Is this too anal? I'm a bit like Jazz on the perfectionism. What is a good source for colored automotive wiring? In addition, what is the best way to splice in new portions of wiring? Solder and shrink tubing? Some sort of fancy connector? Forgive me, I was a history major not an EE.

I would like to fix these problems for good so I don't have to deal with these issues again?

[spazegun2213]

Charlie,
its not anal at all. The best place I've found wiring is from either Home Depot or radio shack. As for color, i always have a few colors in my box just in case i need them, and being anal with wiring is a good thing, it will shave you headaches in the future. If the wire is inside the door any wire the same gauge should work. The best connection is soldering for sure, that and shrink wrap will do the job right.

[Dr K]

Calling CM...Calling CM... Just don't sell your car as soon as someone has helped you replace the wiring.

[Jazzbass]

Originally Posted by Redroc

What is a good source for colored automotive wiring?

Home Depot or any local auto parts store. The autoparts places usually have a good assortment of colors in different gauges.

Originally Posted by Redroc

In addition, what is the best way to splice in new portions of wiring? Solder and shrink tubing? Some sort of fancy connector?

- Best way? Re-run the portion of wire from end to end, using the appropriate open barrel connectors on each end.
- Second best way? One splice from the break to the closest thing with a connector. Splice with a good open barrel crimper then heat shrink 1/4 past the splice on each end for strain relief.
- Third Best? Solder connection with heat shrink.
- Fourth by a long shot? Those crappy red/blue/gold things you get for 50 cents. They suck and will cause more problems eventually.

The problem with the first 2 options is they require special crimping tools (see the 944 rewiring thread). Solder joint can break not at the joint, but where the wire goes into the joint. That's why mfrs don't use them. That said, since a splice is not held fixed at one end like a connector to a component is, it'll be less susceptible to vibration and probably be OK. Make sure to use heat shrink not electrical tape as the insulator.

To be OCD like me, you need to do option #1.

[Trak Ratt]

Originally Posted by Jazzbass

To be OCD like me, you need to do option #1.

but from the fuse panel and add some extra relays, and replace all the grommets, and use new wire ties, etc, etc, add infinitum not that there's anything wrong with that

[Redroc]

Jazz, I'm with you on Option #1 and am actually contemplating this method. A few questions:
1. The typical rounded metal connectors that fit into the plastic housing (say for a power window switch) - Are these removable? Are new ones readily available? Are there different sizes?
2. I just have a crappy multi-stripper/crimper. The selection of wiring tools that you posted a picture of in TD's wiring thread - are these available at Home Depot/Lowe's etc.?
3. On a 944 where the door wiring harness goes through the hinge-area boot and into the car - Do these wires all terminate at a certain location or are they strewn throughout the car? I'm guessing I'll have 5 to 10 wires to replace - Would it make more sense to put a quality connector in-line for the damaged wiring down near the clutch instead of chasing termination points throughout the car?

Thanks for the help!!!

[Jazzbass]

1. Yes, they are removable. Not sure about getting replacement pins, but they are almost certainly a German standard.
2. Crappy won't work. The wire I got mostly came from Home Depot and Advance.
3. It depends, but most likely will go to different areas of the car.

Would it make more sense to put a quality connector in-line for the damaged wiring down near the clutch instead of chasing termination points throughout the car?

This is what I'd do. I like the weather pack stuff from DelCity. You can get an inexpensive crimp tool for about $30 here.

[Redroc]

Just an update on my wiring woes....

Took the door apart and was working on pulling the entire door harness out of the door. Realized I was not going to get the 1" diameter harness and plugs through the three off-angled 1-1/4" holes with out cutting wires. Instead of making things worse, I crammed everything back in the door and took the car to Matt De Maria. One week and one brand new door harness later, I got my car back and all is good again.

Matt said several wires were missing insulation and the insulation on the rest was very brittle. Decision was made to order a new harness from Porsche. Only took 3 or 4 days for harness to arrive from Germany. Not bad!!!

So no Dorki DIY points for me but mad propz to Matt D.!!!