Bulkhead connectors, where to buy/possibly making new ones.

[bunni]

I am doing a pretty major engine overhaul, and in the process of moving things out of the way one of the tabs from the bulkhead engine connectors broke off. Is there any where where those connectors are available other than purchasing new harnesses from DMC/other vendor? If no one knows where I can find them, would anyone here be interested in manufactured reproductions? I have a large experience in mold design and could churn this out pretty quickly, however unless I get a few requests it would not be very cost effective... Let me know what you guys think.

-Kris

[Bitsyncmaster]

I think you can get them with an overseas distributor.

[bunni]

Ahuh, does anyone know of any part numbers? I spent a solid two hours going through a fraction of the connectors manufacturers parts catalog and got no where...

-Kris

[bunni]

Anyone? Know what part numbers would make a good replacement, or any interest in a bulkhead connector kit? I wont bump this anymore if no one else responds.

-Kris

[TTait]

I would send a message directly to Martin in the UK and Ed at DMC-EU...

[Bitsyncmaster]

Anyone? Know what part numbers would make a good replacement, or any interest in a bulkhead connector kit? I wont bump this anymore if no one else responds.

-Kris

I don't think failure of the housings are that common. The connector contacts do fail often but that could be fixed by a kit of new pins. But then you would need the pin extractors and crimper.

[bunni]

Thanks TTait!

Bitsyncmaster, indeed they don't, but mine did. Contact failure is easy to fix...

-Kris

[Farrar]

I tried using a pin extractor on some of the bulkhead connectors and it merely ended up splaying the female terminal such that it could not be removed even by pulling from the other side. It looked to me like the pins are larger than what one would normally find on an Molex connector, at least here in the U.S.

I had thought of ordering some of these (http://www.molex.com/molex/products/listview.jsp?query=&path=cHome%23%23-1%23%23-1%7E%7EncCRIMPHOUSINGS%23%230%23%2346&offset=0&autoNav=1&sType=z&filter=&fs=categoryid%3ACRIMPHOUSINGS%2Cproductname%3A%22S tandard+.093%22&channel=Products), but I was unsure what size terminals are needed, since they obviously aren't the standard off-the-shelf size.

One of my bulkhead connectors (the blue one) has a snapped-off tab, so I am also interested in replacements.

Farrar

[Bitsyncmaster]

Here is the male pin extractor. Worked perfectly on that two pin connector I cut out. No effort at all to remove the two male pins.

I machined it out of 0.375 dia 4130 steel rod. The finished drill size was 0.135" drilled 0.75" deep. The end is turned down to 0.200" dia. 0.300" long. The next shoulder is 0.250" dia. 0.500" long.

Will try to make the female extractor tomorrow.

[Bitsyncmaster]

The female pin (socket) extractor used a drill size of 0.169" and and OD of 0.198". That OD is just a little tight but I keep it that way so the extractor is a little stronger. You really have to be careful with this one because the steel wall of the extractor is so thin. But it seems to work good.

[Bitsyncmaster]

Here are photos of old and new pins. If you can't make it out from the photos, the problem is the female pin (socket) has opened up just a little. That is enough to make the pin have zero tension. With the new pins tension is not to bad but still could be a little more.

[JMLaux]

Here is the male pin extractor. Worked perfectly on that two pin connector I cut out. No effort at all to remove the two male pins.

I machined it out of 0.375 dia 4130 steel rod. The finished drill size was 0.135" drilled 0.75" deep. The end is turned down to 0.200" dia. 0.300" long. The next shoulder is 0.250" dia. 0.500" long.

Will try to make the female extractor tomorrow.

I have gotten these two and they seem to a lot of the terminals in the car. They are for latched terminals and round pin.

Lisle 56500 Terminal Tool (http://www.amazon.com/Lisle-56500-Terminal-Tool/dp/B0009OR906/ref=sr_1_2?ie=UTF8&qid=1313871143&sr=8-2)

Lisle 14900 Wire Terminal Tool (http://www.amazon.com/Lisle-14900-Wire-Terminal-Trouble/dp/B0002STTQG/ref=pd_bxgy_auto_img_b)

I have also found a lot of terminals and some of the bulkhead connectors from this place:

British Wiring (http://www.britishwiring.com/CAT00_35.PDF)

As well as this overseas site in the UK:

Vehicle Wiring Products (http://www.vehicle-wiring-products.eu/VWP-onlinestore/home/homepage.php)

Lots a little goodies on these sites :)

[ramblinmike]

I have gotten these two and they seem to a lot of the terminals in the car. They are for latched terminals and round pin.

Lisle 56500 Terminal Tool (http://www.amazon.com/Lisle-56500-Terminal-Tool/dp/B0009OR906/ref=sr_1_2?ie=UTF8&qid=1313871143&sr=8-2)

Lisle 14900 Wire Terminal Tool (http://www.amazon.com/Lisle-14900-Wire-Terminal-Trouble/dp/B0002STTQG/ref=pd_bxgy_auto_img_b)

I have also found a lot of terminals and some of the bulkhead connectors from this place:

British Wiring (http://www.britishwiring.com/CAT00_35.PDF)

As well as this overseas site in the UK:

Vehicle Wiring Products (http://www.vehicle-wiring-products.eu/VWP-onlinestore/home/homepage.php)

Lots a little goodies on these sites :)

The 'cathedral' bulkhead connectors are on page 26 of the 'British Wiring' catalog above.