S1 Wiring Harness - Wall of shame

[dakazman]

314159td ,
  I actually like the bullets. At first I would agree with you but after soldering in rather than using a cheap crimper I purchased. I’ve worked with them on many motorcycles and seldom have problems. The dielectric is a good idea as is getting the proper removal and insertion tools. The connectors (black) just replace them initially, I have seen them used without the center sleeve in place.
Dakazman

[jbcollier]

+1 on the stock connectors.  Work fine.  I changed all my old ends and used new sleeves.  No issues.  Dialectic grease is a good idea.

[Dilkris]

314159td ,
 "......as is getting the proper removal and insertion tools. The connectors (black) just replace them initially, I have seen them used without the center sleeve in place.
Dakazman

Hi Dakazman - I never new there was a proper tool for these connectors - what does it look like?

[dakazman]

  Dilkris,

   https://search.app/Y49xkkeDur5Soyy9A
 Then tool chesh and scroll down…


   https://www.google.com/gasearch?q=puller%20&%20separator%20tools%20lucas%20bullet%20connector%20removal&source=sh/x/gs/m2/5#piu=ps:44&oshopproduct=pid:7107709475504648293,oid:7107709475504648293,iid:9414602121452599003,pvt:hg,pvo:3&oshop=apv&pvs=0

Dakazman
 

[dakazman]

At $695 for a new wiring harness for a S1 - I think Dakazman's approach is the way to go.

 
   Found this
 https://www.autosparks.co.uk/lotus-europa-wiring-harness-set
   
 At $479 all terminals done with grommet included. It may be worth it. Plus shipping of course.
Dakazman

[314159td]

If you nicely grease or keep an eye on them the bullets are fine...but the idea of maintaining an electrical connector is too much for me. Even doing a concourse restoration, I'd find a way around them. Contact surfaces just all exposed to the elements is a recipe for dim, flickering headlights, as we're all aware

While we're on the subject of harnessing, I'll highly recommend adhesive zip tie mounts and MMA300 or similar aggressive adhesive. Works wonders on the boat harnesses and hoses mounted to fiberglass. I feel like every Europa I've seen irl has some turn signal wiring dangling in the grill.

[Dilkris]

  Dilkris,

   https://search.app/Y49xkkeDur5Soyy9A
 Then tool chesh and scroll down…

Dakazman
 

Thankyou Dakazman, I see the tool is for inserting the bullets, (which I have always managed to "work around") - my problem has always been in separating them, invariably leaving the bullets in situ, and me staring at piece of blank wire.      

[GavinT]

- my problem has always been in separating them, invariably leaving the bullets in situ, and me staring at piece of blank wire.      

Yeah, perhaps the most tortuous test of a bullet connector is attempting to pull it out. These little devils are one instance where the soldered bullets are more reliable than the crimped variety IMHO.

There's likely years of that white corrosion inside the sleeves. This can be dissolved with a vinegar/water solution but I reckon replacing them with new sleeves is a much better idea . . and they're cheap enough.

[dakazman]

 I agree with the soldering, I thought it was just my crimping tool they failed a pull test. I solder many of them .
 In that same note there are bullets for soldering and others for crimping. Ask me how I know🥴.
Dakazman

[Kendo]

If I happened to stock up on the crimp variety, can they be soldered, or are they different shapes, or have different coatings? I bought a bunch a while ago, but am just getting to the electrical phase.

[dakazman]

   Kendo,
    Yes they can be. The soldered ones seem to be harder, maybe thicker, that's probably why I had trouble crimping them.
 Dakazman

[GavinT]

My memory (probably suspect) of the bullet terminals is that the OEM ones were brass 4.7mm Lucas style connector which was of the solder variety.

There's quite a variety of bullet connectors out there - some for crimping because everyone forgot how to solder these days - and there are variations for different wire sizes, too. Perhaps if the same 4.7mm diameter is observed, many might be OK. Remember too that there were smaller bullets used on motorcycles IIRC.

[Dilkris]

I never knew there were so many different "forms" of bullets.
Crimped fittings I am personally not a fan of; I have on many occasions used a crimped fitting, removed the plastic sleeve, fluxed   and crimped the fitting, soldered and then covered the result with heat shrink sleeving. Not a particularly cost effective practice if you were doing this in business.