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Old 02-24-2011, 08:42 PM
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Cloning a Marine Wire Harness

I have a 2001 Glastron GX205 that I bought from a salvage yard that has some fire damage that was started with a ruptured fuel line. I have the harness removed from the boat. The harness isn't completely toast but I don't feel comfortable running it without having problems down the road, I mean the river, lol. The oem harness is still okay (I think) but I want to just start with new wire and clone the harness. I am in the process of ordering the wire and connectors to build the harness. There is only 2 plugs on the harness and that is to plug the electric fuel pump in and plug the engine harness into the main harness, the rest of the connectors are just ring terminals. My question is how should I do this, I mean what type of connectors? Should I just use a shrink wrap crimp connector or should I just use a bare connector and crimp and solder? I am aware that I need tinned copper wire. I think this is pretty basic and simple to do but I thought I would just ask for tips before getting it all done and saying "shoot!" I should have done it this way.

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Old 02-24-2011, 09:12 PM
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On a boat, I would crimp, solder, and then heatshrink, possibly with the heatshrink that has the hot melt glue inside it to seal the connection
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Old 02-25-2011, 04:55 AM
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Be care full of useing RTV to seal the connections.... TRV will cause copper to corrode badly...... don't ask how I know this.
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Old 02-25-2011, 05:34 AM
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There are terminals with heat shrink already on them, they have glue in them to. These are made for this use. You crimp and shrink and they work and hold up in the environment.

They are made by a few companies Anchor, Thomas & Betts, ect. And sold by most auto parts stores now.
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Old 02-25-2011, 05:18 PM
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These are the items that I ordered

http://cgi.ebay.com/ebaymotors/12-AW...ssoriesQ5fGear

http://cgi.ebay.com/ebaymotors/12-10...ssoriesQ5fGear

http://cgi.ebay.com/ebaymotors/12-10...ssoriesQ5fGear

http://cgi.ebay.com/ebaymotors/ATC-F...ssoriesQ5fGear
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Old 02-25-2011, 10:55 PM
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Go to a marina and get one out of a junk boat. Splice the back half with the connectors that heat shrink with glue to seal. There pretty much standard harnesses.
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Old 02-25-2011, 11:09 PM
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I have looked all over ebay and have found nothing for it. There are several different harnesses made for this engine, trust me, I've looked. I will continue to look on ebay for a used harness until I get my clone installed in the boat.
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