Carpokes Porsche Forum

Factory wires are metric and these are AWG, so you'd need to pick the closest. Most of the 944 engine harness wires are 1mm^2, so right between 16 and 18 gauge. The factory wire insulation is also pretty thin compared to the GXL I use on my stuff. An 18 gauge GXL wire, for example, is thicker overall than the 1mm harness wires, even though the actual copper inside is a little smaller. It would get extra bulky if you did the whole harness that way. TXL wire has thinner insulation, though I don't have any handy to compare to the factory wire....

gruhsy wrote: Wed May 18, 2022 3:56 pm That’s good to know.

What gauge wire did you order and was it same size as the factory DME wires?

Darwin wrote: Wed May 18, 2022 2:02 pm

gruhsy wrote: Wed May 18, 2022 10:16 am If anyone wants custom striped wire check out theses guys
Every combination you could imagine

560 color/gauge combination currently.

https://4rcustomswire.com/

That's who I used when I needed some of the OE color combinations. They sell increments as short as 5ft and have great customer service.

Pretty sure the factory used some goofy metric size wire. I built an engine harness using 18 - 22 AWG, primarily 22 AWG with the exception of some of the higher current power/ground needs. A bit more expensive but totally worth it is M22759 wire. The reduction in bundle diameters and branch point bulk itself is worth it...

https://www.prowireusa.com/c-59-m22759- ... -wire.html

Tom wrote: Wed May 18, 2022 4:14 pm Factory wires are metric and these are AWG, so you'd need to pick the closest. Most of the 944 engine harness wires are 1mm^2, so right between 16 and 18 gauge. The factory wire insulation is also pretty thin compared to the GXL I use on my stuff. An 18 gauge GXL wire, for example, is thicker overall than the 1mm harness wires, even though the actual copper inside is a little smaller. It would get extra bulky if you did the whole harness that way. TXL wire has thinner insulation, though I don't have any handy to compare to the factory wire....




metric to awg.jpg

I used 22AWG for branches to sensors and 18AWG for injector/coil power wires. I just matched what Link used for sensors, and did the math to calculate peak current potential to size power wires accordingly with a little safety margin.

I used TXL wire from both 4rcustoms and Prowire. I didn't really see a need to run the Tefzel, but it is good wire if you want to spend the extra money (All things considered, it isn't that much more expensive). I also sheathed my entire harness in Raychem DR-25.

FWIW, I didn't notice a huge difference in sheathing wall thickness between the existing harness wires from Link and the TXL I bought, but I don't have any OE wire handy to compare either. If you're curious, I can dig something out and mic it.

I was actually fortunate enough to get about 300lbs worth of mil-spec wire.

I’m storing it in three overflowing 150 quart bins.

Wire sizes from 10 gauge to 24 gauge.

It’s 600V 200 degree Celsius Teflon coated left over from Phalanx projects.

I don’t have every factory color combo but a freakin ton of white with all color stripes.

4rCustomswire.com I would use for the stuff I don’t have if I want to stay factory color combinations

I had trouble finding all the right combinations I needed from the 4Customs site, so I ended up ordering most of my wire from Sherco Auto. I didn't use TXL or GXL; I used their marine grade wire. From everything that I read prior to starting to make my engine harness, the metric equivalent comes out right about 17 AWG; good luck finding that! I also went with mostly 18g, but up to 16 and some 14 for the thick ground bundles.

Cheers

Just food for thought when choosing a vendor.

Look what certifications they have to avoid counterfeit stuff or garbage made in China.

I forgot about some of the info posted on this Junior Timer thread when I posted my Bosch boot harness thread.

ISO standards

Big indicator for me is ITAR

A vendor that has ITAR certification is not going to risk loosing this certification selling garbage products.

Check out the pics of my flashlight 🫢

It’s a pretty good light source working on cars.

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