Wiring and Harness Fabrication
We offer a wide range in wiring harness types and techniques. Each harness is tailored to every vehicle to prioritize weight, size, flexibility, weather proofing, signal stability and more. They can be built to disappear throughout the vehicle for a super clean setup with functional and reliable results.
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Take a look at some of our experience and capability.
Sleeved Wiring
This option is by far the most cost effective solution however it offers very little for protection and features. It's comprised of individual wires or shielded bundles pulled through a protective sleeve. This sleeve is either a strong woven mesh or a rubber heat shrink tube. Covered with a strong mesh, the wires are protected against abrasion and strain but not water, oil, dirt etc. Therefore each individual junction and connectors must be waterproof. A heat shrink sleeve is desirable when the harness will be exposed to moderate heat or weather conditions. This type of harness is lightweight, reasonably flexible and is easy to repair or add on to.
Concentrically Twisted
Concentrically twisted harnesses are heavier and can take more time to fabricate but are extremally versatile and reliable in harsh conditions. these types of harnesses are made by wrapping a set of wires around a center core, typically a single bundle of shielded cable. It is then wrapped in thin strands to pull the wires together and enable more layers to be added. Many options like Kevlar strand, carbon strand, DR25 Heat shrink, standard automotive wire or Tefzel Motorsport wire are available. This technique is seen in high end motorsports because its extremally reliable, strong, very flexible, dense and fire resistant.
Flat Woven Ribbon
Flat ribbon cables are unique in the automotive world. They take the most time to fabricate but are much lighter and easier to pack into denser spaces. The wires are laid out in a flat side-by-side configuration and are sewn together with carbon or Kevlar strands. They can then be wrapped in weatherproofing such as DR25 heat shrink to make them waterproof and fire resistant. The bundle's stiffness in one direction means they can be designed to absorb vibrations and prevent rattling where as other types of harnesses might not. The extreme flexibility and ultra low profile means they can fit the contour of a tube frame chassis and be routed between body panels.
Connectors
A large variety of connectors are available for different applications and power requirements. Waterproof plastic clip connectors are a good and cost effective option for standard connections that don't require many pins. They are inexpensive and quick to install or modify. Precise aluminum twist lock connectors are required for higher number of connections, dense cables, sensitive data or very large amounts of power. The Aluminum enclosure is waterproof and heat resistant in combination with gold plated pins ensure a super reliable connection.
Sensors and Junctions
On performance vehicles that will be serviced often or have to be repaired on the track, Junctions or integrated sensors save precious time and headaches. Multiple sensors will have wires soldered to their pins and filled with Epoxy resin for a permanent connection. These sensors will then be wired together to a junction with only one or two connectors on them. This technique saves cost in expensive connectors and reduces the size and complexity of a single wiring harness. Fewer connections and modular wiring means if there is a failure or a modification needed, it can be replaced as an assembly at the track.
3D Printed Mounts
Mounting for small electronics such as sensors, buttons, switches and displays are engineered to be compact and lightweight. Using CAD and 3D printing we are able to design a housing that looks good and appeals to the driver. Multiple buttons or switches can be laid out in a natural pattern and accompanied with indicators or a display. They are then wired together to a single connector and installed into the enclosure. Our methods of 3D printing gives many options for testing and prototyping. When the best design is found, we can engineer strength and rigidity into the part as well as using carbon impregnated plastics.