Extending handlebar wiring
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Tourer
Joined: Nov 2006
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Extending handlebar wiring
Hi, I'm putting 16 " apes on my 2006 Standard this winter. This will be my second set of apes I've installed, but want to hear some ideas and other techniques on extending wiring. The first time I used a Novello wiring kit I bought from J&P Cycles which worked great, and I am probably planning on using it again. But I am curious to see what other people used to extend their wiring. The kit I used was 60 bucks...after buying the handlebars and cables, I'm looking for a break.
May our Moderator Rest in Peace
Joined: Sep 2006
Posts: 11,386
Likes: 35
From: Rochester, NY
RE: Extending handlebar wiring
I don't know if your experienced with wiring jobs but just in case here's a web page that will show you in detail exactly how to cut/solder the wires the right way the first time.
If you follow the directions on the page it should turn out to be a completely trouble free job.
http://fordfuelinjection.com/?p=7
If you can't find any of the adhesive lined shrink tubing locally all is not lost. Just swipe a bottle of clear nail polish off the wife or GF and thoroughly paint the joint with it. Make sure you pay particular attention to the insulation ends as the polish once dried will seal the ends up preventing water from migrating up the wire.
Any water that gets inside the insulation will allow the wire to corrode and sooner or later you’ll start having weird electrical problems that can be very difficult to isolate later.
If you follow the directions on the page it should turn out to be a completely trouble free job.
http://fordfuelinjection.com/?p=7
If you can't find any of the adhesive lined shrink tubing locally all is not lost. Just swipe a bottle of clear nail polish off the wife or GF and thoroughly paint the joint with it. Make sure you pay particular attention to the insulation ends as the polish once dried will seal the ends up preventing water from migrating up the wire.
Any water that gets inside the insulation will allow the wire to corrode and sooner or later you’ll start having weird electrical problems that can be very difficult to isolate later.
Stellar HDF Member
Joined: Nov 2005
Posts: 2,272
Likes: 10
From: Orange VA
RE: Extending handlebar wiring
Paid to have someone solder once. A lot of money to spend to have a mech do it.
Soldered my own once. Got done in less time but my labor rate is higher than HD.
Bought extender kits the last time. While somewhat pricey for a few wires and connectors, it was less than the parts and labor expense for a mech or DIY solder job.
Soldered my own once. Got done in less time but my labor rate is higher than HD.
Bought extender kits the last time. While somewhat pricey for a few wires and connectors, it was less than the parts and labor expense for a mech or DIY solder job.
Outstanding HDF Member
Joined: Mar 2006
Posts: 2,374
Likes: 1
From: Central Florida
RE: Extending handlebar wiring
60 bucks for a sew wires? Wow, that's a lot. When I did mine it didn't cost aything. I had some black wire and heatshrink already laying around the shop frop other things that I did. Like Bob said, cut wrap, assemble, ride. Good luck with it and have fun.
Outstanding HDF Member
Joined: Jul 2005
Posts: 2,380
Likes: 3
From: NC
RE: Extending handlebar wiring
ORIGINAL: Citoriplus
I don't know if your experienced with wiring jobs but just in case here's a web page that will show you in detail exactly how to cut/solder the wires the right way the first time.
If you follow the directions on the page it should turn out to be a completely trouble free job.
http://fordfuelinjection.com/?p=7
If you can't find any of the adhesive lined shrink tubing locally all is not lost. Just swipe a bottle of clear nail polish off the wife or GF and thoroughly paint the joint with it. Make sure you pay particular attention to the insulation ends as the polish once dried will seal the ends up preventing water from migrating up the wire.
Any water that gets inside the insulation will allow the wire to corrode and sooner or later you’ll start having weird electrical problems that can be very difficult to isolate later.
I don't know if your experienced with wiring jobs but just in case here's a web page that will show you in detail exactly how to cut/solder the wires the right way the first time.
If you follow the directions on the page it should turn out to be a completely trouble free job.
http://fordfuelinjection.com/?p=7
If you can't find any of the adhesive lined shrink tubing locally all is not lost. Just swipe a bottle of clear nail polish off the wife or GF and thoroughly paint the joint with it. Make sure you pay particular attention to the insulation ends as the polish once dried will seal the ends up preventing water from migrating up the wire.
Any water that gets inside the insulation will allow the wire to corrode and sooner or later you’ll start having weird electrical problems that can be very difficult to isolate later.
Soldering I can do, but the wrap idea looks super easy and the tip about the adhesive tubing / clear nail polish / sealant glue to prevent corrosion is very cool. Thanks
Thread Starter
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Tourer
Joined: Nov 2006
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From:
RE: Extending handlebar wiring
Thanks for the input guys!! Great link on soldering...I gonna go that route this go round...Thanks
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May our Moderator Rest in Peace
Joined: Sep 2006
Posts: 11,386
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From: Rochester, NY
RE: Extending handlebar wiring
ORIGINAL: Babs
Wow.. I learn something cool in here every day. Soldering I can do, but the wrap idea looks super easy and the tip about the adhesive tubing / clear nail polish / sealant glue to prevent corrosion is very cool. Thanks
Wow.. I learn something cool in here every day.
Soldering I can do, but the wrap idea looks super easy and the tip about the adhesive tubing / clear nail polish / sealant glue to prevent corrosion is very cool. Thanks
It works especially well when you have to splice a wire into the middle of an existing line. The tubing doesn’t always shrink quite enough on one side or the adhesive can’t properly seal up the gap between the two wires on the other side.
Its been my experience that if you leave any gap at all, it’s a sure bet that water WILL get in.
Using the nail polish guarantees that even if it isn't sealed completely by the tubing or the adhesive in it, its still has some protection from water and road salts.
The best part is that even if you don't have any polish laying around its only a buck or two in any grocery store for a cheap bottle that will work fine and last for years.
Before you try shrinking the tubing, especially with a Bic or other lighter, be sure to let the polish dry completely, use a hair drier if your in a hurry. Besides being very flammable the acetone or something else in the polish doesn't let some brands of shrink tubing work right when its still wet.
Have fun
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Road Warrior
Joined: Jul 2006
Posts: 1,451
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From: Bealeton, VA
RE: Extending handlebar wiring
Another FYI - if you use regular electrical tape to wrap the joints and then apply some PVC glue (not the 2 part type for white pipe, but the single bottle stuff for grey Sch40 pipe) the pvc glue actually melts the tape around the joint.
As an electrician, I've used this method in various applications, the only way you're getting back to that joint afterwards is to cut the joint out completely.
As an electrician, I've used this method in various applications, the only way you're getting back to that joint afterwards is to cut the joint out completely.