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Post Info TOPIC: 90 Degree Plug Wire Boot Installation Tips/Tricks?
SShink


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90 Degree Plug Wire Boot Installation Tips/Tricks?
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Making new plug wires for the 442, so wondering if anyone has any tips/tricks on how to get the wire through a 90 degree boot easily before crimping on the connector?

I've tried WD40, silicone, etc. and it's still difficult.



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Stan S.-Twin Cities 'South Metro'

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Chris S


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I find it best to use carb spray or brake cleaner on rubber like that. You have to move fast because it dries fast but leaves no residue.



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Chris S.

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John D


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Maybe a dab of Dielectric grease... the same stuff I've put a dab in the boot before snapping them on... so they don't get "welded" to the porcelain in 6 months.

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John D. - St. Louis Park, MN.

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Lost in the 60s


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John D wrote:

Maybe a dab of Dielectric grease... the same stuff I've put a dab in the boot before snapping them on... so they don't get "welded" to the porcelain in 6 months.

 Dielectric grease, that was the name I was trying to come up with in my reply on the front end thread.

I see he gave up on the 90's and reused the straight boots. By the orientation of those to the head, I don't think he wants 90 anyway. Maybe a 45 degree boot. I have 3 sets of boots and ends for my Chevelle now, to get the angle where I want it for the headers ...banghead



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Mitch D.   River Falls, WI

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1966 Chevelle SS 396 M20

1970 Chevelle SS 396 M20

1967 Camaro SS/RS 350 M20
dashboard


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Don't laugh...KY Gel. Water based, cleans up easily, excellent lubricant. Got the tip from my urologist!

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Kevin

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Step 1 - Heat the boots up in ultra hot water,

Step 2 - Lube the wire / metal clip with dielectric grease

Step 3 - Palm the boot in the left hand with the opening facing to the right, with the right hand, hold the wire about 1" or less and stick the wire in the boot and keep pushing / rotating the wire back and forth with the until seated.

Repeat



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John E - Rogers, MN

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Chris R


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Dialectric grease, petroleum jelly or Sil-Glide are what I have always used when I was a tech in the field and at home.



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Chris - Ramsey, MN.

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SShink


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Lost in the 60s wrote:
I see he gave up on the 90's and reused the straight boots. By the orientation of those to the head, I don't think he wants 90 anyway. Maybe a 45 degree boot. I have 3 sets of boots and ends for my Chevelle now, to get the angle where I want it for the headers ...banghead

Thanks everyone for the tips.  Sounds like I'm not the only one that struggles with these!

Mitch, the straight boots you saw in the pic of my table go on the engine end since Olds engineer's were smarter and put the plugs above the exhaust/headers, so easy access to them.  razz

Related question, I watched a couple of YouTube videos for tips, and in one they stripped the black coating off the inner wire before bending over and crimping.  I don't know that I've ever stripped the center conductor and they always seemed to work.  Do you guys strip the inner conductor also? 



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Stan S.-Twin Cities 'South Metro'

1972 Malibu Convertible 2nd time around 

2001 Mustang GT Convertible 

Forum influenced terms: 'Link Paste', 'Stanitized', & 'Revolving garage door...' 

 
SShink


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dashboard wrote:

Don't laugh...KY Gel. Water based, cleans up easily, excellent lubricant. Got the tip from my urologist!

I know you're being serious...but laughinglaughinglaughing 



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Stan S.-Twin Cities 'South Metro'

1972 Malibu Convertible 2nd time around 

2001 Mustang GT Convertible 

Forum influenced terms: 'Link Paste', 'Stanitized', & 'Revolving garage door...' 

 
Larry Lucast


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I was told to cut the end of the wire at a 45 degree angle so it follows the corner.

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Larry L.

Coon Rapids
SShink


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Larry Lucast wrote:

I was told to cut the end of the wire at a 45 degree angle so it follows the corner.

Now that sounds like something to try.  Thanks Larry! 



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Stan S.-Twin Cities 'South Metro'

1972 Malibu Convertible 2nd time around 

2001 Mustang GT Convertible 

Forum influenced terms: 'Link Paste', 'Stanitized', & 'Revolving garage door...' 

 
Lost in the 60s


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SShink wrote:
Lost in the 60s wrote:
I see he gave up on the 90's and reused the straight boots. By the orientation of those to the head, I don't think he wants 90 anyway. Maybe a 45 degree boot. I have 3 sets of boots and ends for my Chevelle now, to get the angle where I want it for the headers ...banghead

Thanks everyone for the tips.  Sounds like I'm not the only one that struggles with these!

Mitch, the straight boots you saw in the pic of my table go on the engine end since Olds engineer's were smarter and put the plugs above the exhaust/headers, so easy access to them.  razz

Related question, I watched a couple of YouTube videos for tips, and in one they stripped the black coating off the inner wire before bending over and crimping.  I don't know that I've ever stripped the center conductor and they always seemed to work.  Do you guys strip the inner conductor also? 

 Ah, you need the cap ends on. Those boots are harder to bend straight to shove the wire thru. Larry's suggestion sounds helpful.

I usually buy a set with the cap boots finished and only cut to length on the plug end.

ALWAYS strip about 3/8" to bare and fold over under the terminal.



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Mitch D.   River Falls, WI

Lifetime member of the "Cars apart Club"

1966 Chevelle SS 396 M20

1970 Chevelle SS 396 M20

1967 Camaro SS/RS 350 M20
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