Wire Like A Pro: Peeking Into Wire Harness Mastery

There are many ways to learn, but few to none of them compare to that of spending time standing over the shoulder of a master of the craft. This awesome page sent in by [JohnU] is a fantastic corner of the internet that lets us all peek over that shoulder to see someone who’s not only spent decades learning the art of of creating cable harnesses, but has taken the time to distill some of that vast experience for the rest of us to benefit from.

Wire bundle

This page is focused on custom automotive and motorcycle modifications, but it’s absolutely jam-packed with things applicable in so many areas. It points out how often automotive wiring is somewhat taken for granted, but it shouldn’t be; there are hundreds of lines, all of which need to work for your car to run in hot and cold, wet and dry. The reliability of wiring is crucial not just for your car, but much larger things such as the 530 km (330 mi) of wiring inside an Airbus A380 which, while a large plane, is still well under 100 m in length.

This page doesn’t just talk about cable harnessing in the abstract; in fact, the overwhelming majority of it revolves around the practical and applicable. There is a deep dive into wiring selection, tubing and sealing selection, epoxy to stop corrosion, and more. It touches on many of the most common connectors used in vehicles, as well as connectors not commonly used in the automotive industry but that possess many of the same qualities. There are some real hidden gems in the midst of the 20,000+ word compendium, such as thermocouple wiring and some budget environmental sealing options.

There is far more to making a thing beyond selecting the right parts; how it’s assembled and the tools used are just as important. This page touches on tooling, technique, and planning for a wire harness build-up. While there are some highly specialized tools identified, there are also things such as re-purposed knitting needles. Once a harness is fully assembled it’s not complete, as there is also a need for testing that must take place which is also touched on here.

Thanks to [JohnU] for sending in this incredible learning resource. If this has captured your attention like it has ours, be sure to check out some of the other wire harness tips we’ve featured!

splice-cad assembly

Splice CAD: Cable Harness Design Tool

Cable harness design is a critical yet often overlooked aspect of electronics design, just as essential as PCB design. While numerous software options exist for PCB design, cable harness design tools are far less common, making innovative solutions like Splice CAD particularly exciting. We’re excited to share this new tool submitted by Splice CAD.

Splice CAD is a browser-based tool for designing cable assemblies. It allows users to create custom connectors and cables while providing access to a growing library of predefined components. The intuitive node editor enables users to drag and connect connector pins to cable wires and other pinned connectors. Those familiar with wire harnesses know the complexity of capturing all necessary details, so having a tool that consolidates these properties is incredibly powerful.

Among the wire harness tools we’ve featured, Splice CAD stands out as the most feature-rich to date. Users can define custom connectors with minimal details, such as the number of pins, or include comprehensive information like photos and datasheets. Additionally, by entering a manufacturer’s part number, the tool automatically retrieves relevant data from various distributor websites. The cable definition tool is equally robust, enabling users to specify even the most obscure cables.

Once connectors, cables, and connections are defined, users can export their designs in multiple formats, including SVG or PDF for layouts, and CSV for a detailed bill of materials. Designs can also be shared via a read-only link on the Splice CAD website, allowing others to view the harness and its associated details. For those unsure if the tool meets their needs, Splice CAD offers full functionality without requiring an account, though signing in (which is free) is necessary to save or export designs. The tool also includes a version control system, ideal for tracking design changes over time. Explore our other cable harness articles for more tips and tricks on building intricate wire assemblies.

Continue reading “Splice CAD: Cable Harness Design Tool”

How To Lace Cables Like It’s 1962

Cable harnesses made wire management a much more reliable and consistent affair in electronic equipment, and while things like printed circuit boards have done away with many wires, cable harnessing still has its place today. Here is a short how-to on how to lace cables from a 1962 document, thoughtfully made available on the web by [Gary Allsebrook] and [Jeff Dairiki].

It’s a short resource that is to the point in all the ways we love to see. The diagrams are very clear and the descriptions are concise, and everything is done for a reason. The knots are self-locking, ensuring that things stay put without being overly tight or constrictive.

According to the document, the ideal material for lacing cables is a ribbon-like nylon cord (which reduces the possibility of biting into wire insulation compared to a cord with a round profile) but the knots and techniques apply to whatever material one may wish to use.

Cable lacing can be done ad-hoc, but back in the day cable assemblies were made separately and electrically tested on jigs prior to installation. In a way, such assemblies served a similar purpose to traces on a circuit board today.

Neatly wrapping cables really has its place, and while doing so by hand can be satisfying, we’ve also seen custom-made tools for neatly wrapping cables with PTFE tape.