How automotive Mil-Spec wiring can improve your car’s electrical system

power cables

The nervous system of a car is wiring that passes through the chassis and transmits electrical signals to other systems and control modules. This mass of wires should be reliable and consistent and be able to be used for many years in harsh conditions (repeated sun exposure, rain, dust and dust, etc.). The mass of these wires, connectors and wiring looms also reduces weight.

Typical OEM wiring devices weigh more than 70 pounds. Its weight causes serious harm to vehicles, such as racing cars, which try to diet. The thickness of a standard wiring loom can be an important factor, even if the space is minimal or you want to hide the wiring as clean as Shoka. Wiring has various aspects that can affect car fabrication, and by meeting these factors and requirements, the Mil-Spec wiring market has been formed.

Automotive Mil-Spec wiring is derived from standardized and certified wiring used in military and aerospace applications. Real military specification wiring is manufactured in a strict environment to ensure the robustness, reliability and purity of the materials used, such as copper inside the wire. All these requirements and standardization are aimed at increasing the reliability and reliability of electrical systems.

Mil-Spec wires are Teflon coated to shield them from RF signals to prevent electrical interference. Electrical pins are gold to ensure the best possible electrical signal. For planes flying in the air or tanks fighting in desert battles, there is no room for electrical problems. Car versions differ in that they do not have certification. The fact that there are no certificates reduces the cost of various components. The car Mil-Spec bulkhead is smaller compared to the aerospace and military versions.

Mil spec wiring design considers weight and space-saving. “Because there are more strands per cable, they can carry more current than non-mill-spec wires of similar size,” said Mark Sanchez of Advanced Engineering West, whose wires are smaller than unspecified wires. This allows you to use smaller cables to support electrical components, and smaller wires lead to smaller wiring looms, which are like lighter wiring harnesses.

Most bulkhead connectors in OEM applications are large rectangular plastic connectors. Mil-Spec connectors are circular and sealed with O – rings and fixed rings. By comparison, it is small in size and requires only a 1-or 2-inch hole to allow wiring to pass through the firewall. Automotive Mil-Spec bulkhead is available in stainless steel, aluminium and plastic. Mil-Spec wiring has become wiring for expensive car builds, off-road trophy trucks and racing boats.

All wiring looms first start with a diagram or plan. The pattern of electrical connectors and components is drawn, the appropriate AWG wiring and the required wire length are determined.

Unlike conventional crimpers, Mil Spec wiring requires a specific tool consisting of a wrench and a removable turret. The industry standard Crimper is Daniels Manufacturing Corporation (DMC) M22520-1-01 Standard Indent Crimp Tool. This tool requires a turret, which is sold separately. Turret DMC M22520-01-02 has 3 holes. Each hole is a different colour, indicating the size of the largest wire that can be crimped. On the side of the turret, there is a chart indicating the hole to secure the pin among the three holes. The choice of holes depends on the pin and wire size. The dial switch on the handle is used to determine the jaw or crimping depth. It is a very complex crimper that is closer to surgical tools than a typical standard wire crimper. This complexity leads to a higher price of $ 400 or more for handle and turret assemblies.

James Lin Motorsports (JLM), an electronic solutions specialist and Motec distributor, designs and builds Mil-Spec wiring harnesses for customers and advanced users in the auto racing industry. When the customer sends the wiring specifications, the wiring harness strategy is shown in a diagram. Then the wiring technician passes the plan and begins to compile electrical components. Use Mil-Spec wire of various colours to distinguish the wire from other wires. The fact that the wires are coloured is relatively new in the world of Mil-Spec, where the wires were offered only in white. Bulkhead assemblies with associated retaining rings and O – rings match large heat shrink tubes that protect pins and connectors from elements. After the wiring harness is completed, pour electric epoxy on the back of the heat sink tubing to completely seal the connector.

The complexity and time required to create a wiring harness can range from thousands of dollars to more than $ 18,000 for a full wiring harness for a trophy truck. These prices are atmospheric but are a must for race teams that rely on JLM’s expertise and years of wiring experience. And for Motec customers, wiring looms made by distributors are a must if you want a warranty.

JLM does not sell directly to the public, but ProWire USA and Aircraft Spruce do. We offer all the wiring, pins, connectors, shrink tubes and epoxies that JLM uses for expensive wiring looms. They also sell crimpers and turret assemblies.

With the right components and equipment, you can benefit from the better connectivity, lighter weight, smaller wires and overall neat appearance provided by Mil-Spec wiring.