Let’s Get Started! These videos are designed to give the repairer a better understanding of the limitations when repairing a wire harness assembly. The basic rules you will learn through these videos will help you, the repairer, to make good decisions and sound repairs.
In these videos below, you will find common terminology that we constantly use throughout the whole process. Underneath the videos, you will also find a helpful guide that highlights and defines our key terms.
Six Inch Rule This video explains the restrictions you might face when a wire is damaged within six inches of the termination point.
Six Wire Rule
In this clip, Carl will walk you through the number of allowable wires that can be repaired in a wire bundle.
What to do when damage exceeds the 6x6 rule
Here, Carl illustrates what to do when the damage in your wire harness exceeds the six inch rule.
Wire- a long, thin flexible piece of metal which electricity can travel through. There are all different shapes and sizes and copper is the best-known type of wire.
Wire gauge- is measured using one of two standards, the first is American wire gauge (AWG) and millimeters (MM), and the size is determined by the diameter of the wire.
Wire harness- is a group of bundle of wires that make up many circuits of an electrical system.
Connector or Housing – this is usually a plastic device with insulating and weatherproofing properties, which allows current to pass through it, to provide electricity to a circuit or a component.
When referencing whether a connector is male or female, Aeromotive will always use the terminal/contact to determine the connector’s orientation.
Aeromotive references all housing by the terminals orientation (Male/Female).
Terminal- is metal alloy that is mechanically crimped onto a wire and provides an electrical connect of two or more wires. The terminal is housed or protected inside a connector.
Male (reference picture)
Female (reference picture)
Seal- the seal is designed to weatherproof the contacts from outside elements, i.e rain, condensation, debris etc.
Shroud, trough- is typically a plastic guard that helps to protect the wire bundles from outside elements provides routing through the vehicle and reduces the effects from vibration.
Circuit- is a path that allows electrical current to flow within a wire to power or trigger a device.
Split loom- a plastic covering that surrounds a wire bundle to protect the wiring from outside elements, chaffing and vibrations. It is typically ribbed for strength.
Clips, fastener- these are used to tie down a harness assembly to rigid structure to protect it from vibration and chaffing.
Shielded wire- is an electrical cable of one or more insulated conductors enclosed by a common conductive layer designed to reduce electromagnetic interference.