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Old 07-15-2010, 11:38 AM
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wire organizers

Looking for the right plug wire organizers for my 68 chevelle 396 with headman headers. There seems to be a lot of choices and i don't want to make a mistake. I was wondering if someone has been through this process and could give me a recommendation.

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Old 07-16-2010, 11:13 AM
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Originally Posted by buisoma
Looking for the right plug wire organizers for my 68 chevelle 396 with headman headers. There seems to be a lot of choices and i don't want to make a mistake. I was wondering if someone has been through this process and could give me a recommendation.
Much depends on how much weight you put on "style" as opposed to "function".

A perfectly serviceable wire separator can be made by using nothing more than tie wraps, for instance.

But instead of going into any specific design (other than to say I like THIS type of simple separators), I'll instead try to offer some guidelines that may (or not lol) help you make a choice.

Wires will create an induced current in them that can jump from one wire to the other if the wires are run parallel to one another while touching. The longer the run is, the more likely for this to occur so avoid this whenever possible.

If wires need to cross one over one another, do this as close to 90 as practical.

Metal looms or separators will conduct electricity (no kidding! ), so if they're grounded they should be insulated.

On the other hand, I installed a set of SS braided ignition wires for a buddy, they came w/a metal clamp/separator affair w/a wire pigtail coming from it that was designed to be grounded, so there you go... But I'd have to recommend that the steel braided wires be avoided for most applications- they end the braid well short of the plug end, so they don't even offer much header heat protection. All about "style", I suppose.

Generally speaking, if you look closely at an OEM plug wire set-up, it can show you quite a bit about what's needed for a good installation- the wires will be separated from touching, they're routed away from heat sources, the wires are the correct length (nothing looks worse than plug wires wrapped twice around the distributor cap when the "universal" pre-terminated wire sets are used).

Couple other tips:

Use silicone spray to install the boots onto the wire if you have a "cut to fit" wire set. Use a GOOD terminal tool to install the terminals onto the wire, and pay close attention to how you bare the center conductor, that it's not damaged in the process.

Use dielectric grease inside the plug boots, but be sure that you relieve the pressure created when you push the boot onto the plug, otherwise when it gets nice and hot, the boot can be pushed off of the plug. Same thing on the cap end. I've used a WD-40 straw put into the boot from the top (between the wire and boot), then install the boot, remove straw. No pressure.

There are various insulation sleeves that can be used to keep the headers from burning the wires or boots. I've found this material at electrical surplus outfits before (like Skycraft in Orlando). A LOT cheaper than the Moroso sheathing I have in the shop...
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