Cost-Effective Way To Replace Engine Wiring Connector?

[Ryan87LX]

I'd like to replace some of the wiring on my boat, including the harnesses for the engine. Doing the wiring is no problem, but finding a cost effective way to do this is another matter. It appears that the only way to replace the connector on the side of the engine is to replace both harnesses - at a cost of at least $400.

I'm considering building my own harnesses and using weatherpack connectors for the wires. Is there any reason that I shouldn't do this? Are there sources for replacement connectors that will allow me to build my own harness?

Ryan

 

[sutor623]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

What motor is it. I usually cut back past all the corrosion, and splice in new wires as close to the harness as I can. It has always worked very well for me.

 

[Ryan87LX]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

I'm trying to nail that down specifically, but I *Think* it's a 1963 850

That's worth a try. Thanks.

 

[sutor623]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Yeah man, worst case is that you have a weak connection somewhere, and just end up needing to replace everything anyway. Two things to keep in mind. Tape up the wires individually around each of the splicers, then tape all the wires together as the originals were. I try and use marine grade wire(tin dipped/coated), so that the corrosion doesnt start ruining the wires within the next 2-5 years.

 

[sutor623]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Oh and one other thing. DO NOT use smaller guage wire than what you are replacing. Gas fumes plus hot thin electrical wire, whilst on the water, you get the point.....

 

[Silvertip]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

There are lots of water resistant connectors on the market and even if you needed to use two of them rather one big one, the electricity doesn't care. You simply need relatively tight connections because of the wet conditions.

 

[oldman570]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

A good shot of dielectric greese in the conections will keep the corrision at bay for a long time. Wire for big trailors sodered and heat shrink will let you move the conection to the boat where the conectors can be mounted also.That way you would have no conections except the wires inside the coweling where the hook to there post and where you put the one frem the controls. This is how I did mine when it went bad from the UV rays drying out the exposed wire.
Wire cables can be bought at most RV sales and semi truck sales.
Just a thought,
Oldman570

 

[smokeonthewater]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

oldman just hit it.... I was just gonna suggest getting a cord with all the wires you need and running it from the connections inside the cowling to a terminal strip under the dash... then also if electric start, run new 4 ga battery cables and heat shrink the battery cables to the first few feet of the control cable.

if you need a grommet big enough to fill the hole you can mold your own from black rtv...

you could also use a holesaw to make a grommet from starboard... drill the inner hole(s) just a little small and cut a slit in one side to allow it to open up enough to get your cable(s) in

 

[Ryan87LX]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Some really good ideas here, I like them a lot. Thanks!

 

[ajgraz]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Those old 60's and 70's Mercury harness connectors are crap. They are not well sealed and they corrode inside the connectors themselves. New old stock won't save you, they corrode just sitting on the shelf.

When my 78 Merc OB needed a new internal harness, I tried used, I tried NOS, I considered making my own using Weatherpacks. Then I decided, for how often I take my motor on and off the boat (as in, never? Or at least not until it needs a repower) I would just go ahead and do away with connectors altogether and just run the control box wiring straight into the cowl, make the ends of those wires into the internal harness, and bypass connectors altogether. (Luckily I had enough slack for this)

http://forums.iboats.com/showthread.php?t=387130&highlight=harness

 

[Ryan87LX]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Thanks ajgraz. What made you turn against weatherpacks? Is there a downside I don't know about?

 

[ajgraz]

Re: Cost-Effective Way To Replace Engine Wiring Connector?

Late response, haven't been on in awhile.

I did not use the weatherpacks only because I did not need to, I had enough slack wire harness from the control box to go all the way into the cowling without needing any connectors. If I had not had that slack, I would have used the weatherpacks in a heartbeat.