We hope that the pictures below will give you a sense of the attention we give to every harness order. As you can see, every harness is built by hand to guarantee that it fits correctly and looks like it would have when your vehicle rolled off the assembly line. The process is long and involves many stages, but we pride ourselves on the quality of the final product.
Take-out harnesses usually appear in this condition. It is our goal to recreate the original appearance and functionality of the harness.
Using a 1:1 scale pattern, each harness is built to order. Careful attention is paid to wire gauge, color, covering, terminal ends, connectors, configuration, wrappings, and pigtail lengths.
Working on long benches, the wires are cut and bundled according to the pattern. The bundles of loose wires are then wrapped with the type of wrapping used on the original harness.
A common harness covering on vintage trucks is a cloth braid as seen on this portion of a WWII White Half-Track harness.
Special braiding machines are used to braid a harness. The fabric braiding machine has many spools of thread which are spun by the machine around the wire bundle.
Some wiring harness sections have a metal wire braiding such as this #A-1665 headlight wiring harness used on WWII jeeps.
Wire braiding or “shielding” is accomplished using another braiding machine loaded with spools of tinned copper wire instead of thread.
After the harness is covered, correct terminal ends are applied and crimped. After crimping, the terminal ends are also soldered into place to insure accuracy and performance of the connection.
Smaller harness sub-assemblies needed for the harness are assembled, tagged and bagged. The entire wiring system is boxed and a detailed instruction book is included to identify each wiring assembly and installation.