Race Harness construction

Here at JB-Tech, we take great pride in what we do. Our race level harness take awhile to build, but as my old man would say, “you cant rush perfection”. Years of working with harnesses has cultivated a work flow that produces top shelf harnesses that endure the riggers of extreme racing environments…not to mention look snazzy too. Concentric twisted constructions allows for an extremely flexible and resilient harness. Each layer is twisted the opposite direction of the prior layer, this construction is similar to how wire rope is built. Once each layer is completed it is bound with a flat braid to hold it all in place. A lot of time goes into properly mapping out the layers so branches and splices can be properly executed while maintaining strain relief and flexibility. The jacketing material in which is used, is called DR-25, it is the industry standard for motorsport harness jacketing, fuel, oil and chemical resistant, stable in high heat as well as extreme cold, abrasion and puncture resistant, this is the snake skin that protects all those wires inside. Speaking of wire, the wire in itself is not your run of the mill wire. Everything we use in a race harness is MIL Spec M22759/32-XX-X or better known as Tefzel. Tefzel is a ETFE radiated cross linked polymer used as the insulation (much like teflon), it is highly abrasion resistant, and rated for high heat. The internal core of the wire is tin plated copper with a high strand count. This makes the wire in its own, very tough, and does require special tools to work with properly. Once we have branches all made, the ends at the connector are carefully stripped with tefzel specific strippers, crimped using various specialized crimping tools and then terminated into connectors. Depending on the connector a boot may be used to seal the back of the connector, these “boots” are specialized rubber molded parts that shrink and conform to shape when heated. Molded transitions are also used at branches and break outs. All boots are sealed with a polymer epoxy to keep the elements out and strain relief at a maximum. All of this plus hours of planning, mapping, measuring, and datasheet consulting go into every single race harness we build.