Topic

Just finishing up the little bits and bobs on the TF.

Broken boot lid wiring seems to be a common problem.
This is my take on sorting it out.

Six of the seven wires had broken clean away and the last one was cracked.
It seems to me that the main problem is the way the cable is run through a plastic sleeve that allows very little flexibility. The plastic will bend at its weakest point crushing the cables inside and eventually they will simply break!
I have rerun the harness to the right hand side of the hinge bar and run the cables through woven nylon sleeving, this allows the harness to flex over a much longer area.
I'm going to replace the tywraps with a proper 'P' clip.


The cables are going run to the right of the hinge bar.


Here the cables have been spliced, soldered and shrink sleeves fitted. Don't forget to put the sleeves on before putting the wires together and soldering and the woven sleeving must be slipped on before any of the wires are spliced.


The final result allows the harness to flex over most of its free length.

Geoff.

What were the indications of the wires being broken??

No high-line brake light, no interior boot light, blown fuse and three wires sticking out of the plastic sheath where it had fractured.
It didn't seem to have any effect on the alarm system even though the boot lock switch is linked to it.

Geoff.

Mine started with the boot alarm occasionally going off when i opened it, then the middle brake light going.
I would also say that you were actualy quite lucky, mine failed a lot closer to the main loom and I had to unpick the whole lot to get enough cable to connect to!

Mickle5 wrote: wrote:

Mine started with the boot alarm occasionally going off when i opened it, then the middle brake light going.
I would also say that you were actualy quite lucky, mine failed a lot closer to the main loom and I had to unpick the whole lot to get enough cable to connect to!

That is awkward as it's right under the wing.

I think the two main failure points are next to the loom like yours and where it's fixed to the boot hinge bar like mine.

Either way it's going to break that's why I think it makes sense to put a much more flexible sleeving on and re route the harness to the right of the bar.
Ideally it would have been nice to extend the harness a bit so as to clip it out of the way and look neater but the weather was against me, as it is the harness doesn't go near anything.

Geoff.

I have been wondering about adding in a section of curly cable.

Had the same issue, no high level brake light and interior light not working, 5 broken wires. Stripped them back and solder repaired them, re insulated but I have not ty wrapped them back to the hinge. They seem to be clear of any potential traps and have less stress.

I keep thinking of repairing mine before it breaks

I like the nylon mesh cable cover very tidy.

talkingcars wrote: wrote:

I have been wondering about adding in a section of curly cable.

Actually that's not such a good idea.
First of all you need to find some 7 core coiled sprung cable that will take the current then you'll need to make sure there's room for it cos it'll be big and heavy.
My idea of using woven nylon sleeve makes the finished loom thin, light and flexible plus it's pennies to buy.

Geoff

I've just scanned the web for a suitable cable with no luck
but
I like a challange - click me

And there's more - physical shape - click here

talkingcars wrote: wrote:

I've just scanned the web for a suitable cable with no luck
but
I like a challange - click me

Struth; wouldn't you rather be driving it the car

Geoff.