Motorsport Electrical Connectors

Overview

• Professional motorsport harnesses experience high abuse and frequent mating cycles.
• Circular metal-bodied connectors are preferred for their durability and easy mating using a quarter-turn locking mechanism.

Connector Types

• Two main manufacturers: Soriar (8STA range) and Deutsch (Autosport range).
• Connectors are often intermixed in harnesses.
• Choice often depends on availability from suppliers.

Specifying Connectors

• Essential to know the number of wire connections and current passing through each pin.
• Connectors available in various shell sizes and pin densities.
• Shell size determines physical size, mounting hole spacing, and sealing boot size.

Connector Components

• Consist of a plug and a receptacle, forming a mating pair.
• Must share shell size and conductor cavity configuration.
• Available with male pins or female sockets.

Connector Styles

• Receptacle bodies available in flanged (for mounting) and free-hanging versions.
• Common to refer to connectors by shell size and conductor configuration.

Example: SORIAR 8STA0-1835SN

• 8STA: Connector classification.
• 0: Flanged receptacle.
• 18: Shell size.
• 35: Conductor configuration (66 x 22 gauge pins).
• SN: Sockets with red band keying.

Mating Connectors

• Example: 8STA6 1835PN (free-hanging plug with pins).
• Use the red band keying for matching connectors.

Crimping Process

• Use manufacturer-specified tools for crimping (e.g., Daniels Manufacturing DMC AFM8).
• Tools ensure correct crimp pressure and location using positioners.
• Correct strip length and crimp settings are pivotal for reliable connections.

Inserting Pins

• Use specific insertion/extraction tools to avoid damaging connectors.
• Ensure proper insertion by listening for a click and conducting a visual inspection.

De-Pinning Process

• Use the extraction end of insertion/extraction tools to safely remove pins.
• Exercise caution to avoid connector damage.

Wire Specifications

• Correct wire type (e.g., Tefzel M22759/32) is crucial for proper insertion and extraction.
• Mismatched wire sizes can hinder de-pinning.

Pinning Order and Service Loops

• Pin connectors from the inside out.
• Use service loops for strain relief and ease of future repairs.

Example: Potted Engine Position Sensors

• Using ASL0605SN connector for miniature applications.
• Strip wires and crimp pins using correct positioners and settings.
• Insert service loops during pinning for strain relief.

Best Practices

• Use correct tools and follow detailed procedures for reliable harnesses.
• Plan thoroughly for connector assembly to ensure durability.

Course Information

• Course covers basics to advanced techniques in motorsport electrical connectors.
• Available for enrollment for skill advancement.