How to Make a Cable Harness

Cable or wire harnesses, assemblies, and looms are bundles of cables or wires that transmit signals or electrical power. They are widely used in automobiles and heavy machinery. Wires bundled in a harness have an advantage over loose wires in that they remain organized, clean, save space and are less apt to short. There are many options for binding wires into a harness, including cable ties, electrical tape or conduit. Each has advantages and disadvantages. Cable ties don't protect wires against the elements. Conduit may not have the flexibility necessary for tight spaces. Electrical tapes adhesive can melt and ooze at higher temperatures. One of the best ways to ensure the optimal protection for automotive and machine wiring is to wrap them in harness tape. Harness tape has no adhesive to melt, making it a good solution for managing groups of wires.

Instructions

1

Use an X-Acto or other sharp knife to carefully cut the tape away from the wires if you are repairing an old or damaged taped harness.

2

Inspect the individual wires closely for any signs of brittleness, breaks or cuts in the insulation. Replace any wires with new, matching ones.

3

Lay the wires out on a flat surface and pinch them together to form a bundle.

4

Reel some harness tape off the spool and wrap it around the bundled wires in a spiral fashion, from one end to the other, making sure all the wire is covered. Leave enough wire exposed at each end to make any necessary connections.

5

Pull off an extra 6 to 8 inches of tape from the spool when you reach the end of the wire bundle. Twist the tape numerous times to fashion it into a string, wrap it around the end of the bundle two or three times and tie it into a knot to keep the tape from unraveling.