Whether you are repairing one spark plug wire or hand-crafting a complete set, proper connections are critical for a successful result. Errors in part selection or assembly might create ignition system malfunctions rather than boost performance. Attention to some minor details can render a set of custom wires from a spool of high-quality cable and a varied selection of terminals and boots.
Instructions
- 1
Slide the small end of the appropriate boot over the end of the plug wire until the wire extends 2 inches beyond the other end of the boot. Strip off enough insulation to expose 3/4 inch of the wire core. Cut off the cable and repeat the process if the core appears frayed or damaged.
2Fold the exposed wire core over the cut edge of the insulation and up the side of the wire. Insert the wire into the terminal valley with the exposed core against the metal, parallel to the wire. Ensure the wire fills the full length of the area to be crimped.
3Hold the wire in position in the terminal end, and pre-crimp the terminal with the appropriate size pliers' jaw. Position the "W" jaw of the pliers over the terminal end. Firmly crimp the terminal with the gap in the terminal end aligned with center point of the "W." Crimp the full length of the terminal end in a uniform manner, then slide the boot into place.
