Today I visited Autosparks nr Nottingham to have a look at how they are building me a new wiring loom. I thought it sounded interesting and they were only too glad to welcome me and allow me to take a few pictures.
They build a wide variety of looms for a huge variety of cars at the factory which is quite a big operation in fact. They hold large stocks of the different colour, thickness or wire and can also add a brading to wire if required using the brading machine which is pretty neat.
They hold several thousand types of loom as samples and the measurements etc are taking from the sample and a schematic plan produced. This is cross referenced with the wiring diagram to see if there might be any issues. With the loom plan laid out the wires are first cut to size before a peg board is laid out to indicate the general shape and size of the loom. The wires are laid out according the the plan and where required connectors are added to secure the loom and help assist with the assembly.
Stocks of wire
Wire cut to size and type
A huge range of connectors in stock
The braiding machine (not used for a Dolomite but still cool)
Once the loom is completed it must then be wrapped using a loom tape. This tape is not sticky but it does sort of stick to itelf as it is wound on. The ends are usully finished in heat shrink to stop it from unravelling. Then bullet connectors and other pieces are crimped or soldered on before the loom is checked over for faults. Then the loom is finished and ready to be held either as stock or direct to customers like me.
A near finished late Mini loom
I opted to have a complete loom as it seemed easier. It is pretty standard except I have opted to add some relays to the headlights which are also fused. As you can see the main loom is currently set out on the peg board but the rear section and the dash section are nearing completion. These can be plugged into the harness quite easily.
Here's the plan for my loom
The loom is laid out on the peg board
The dash loom plugs in easily
Added relays, need to find a home for the box
One of the looms awaits final testing, I forget which one.
So there's still some way to go on my loom but it should be with me in the next few weeks. In case you fancy your own brand new loom then be quick as it'll be easy and quick for them to make one as the board is already laid out. They have not made a Dolomite one in a while and this is a one off. By contrast the board on the other side was for a Jaguar MK2 and they were making 35 off for stock! The price for a complete loom including the mod was £400 which given the work that goes into it I think is actually very reasonable.
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At the risk of being misunderstood, your thread is pretty dull Mark.