Splicing a HT lead!

Arsytee

Seaman Apprentice
Joined
Oct 8, 2012
Messages
43
So I was checking my spark plugs today and I noticed that one of my HT leads on my DT40 felt a little limp. It must have had a hard life as its been repaired before and has a sort of splint midway with cable ties round it. Anyway, it felt limp due to a split in the original insulation and the electrical wire has corroded all the way through!.

I repaired it by pushing some copper wire either way in the split, making sure it was touching both ends of the existing broken wire, wrapping some plastic sleeving round it and then cable tying it. Presumably this is what the previous repair was.

My HT leads run directly to the CDI unit which is a sealed unit so I can't just replace that 1 lead. My question is, can I buy a single HT lead, cut the ends off and sort of splice the new one with the plug end, on to the old one near the CDI unit? Has anyone had any experience or tried this or something similar. Thoughts please.
 

Bosunsmate

Admiral
Joined
Apr 7, 2012
Messages
6,129
Re: Splicing a HT lead!

Hi, thats exactly what ive just done. I had the same problem that the ht lead goes straight into the cdi unit. I used one of those plastic electrical connectors that you put a wire in each end and a screw then clamps down on the wire on each end. I didnt want to pay for a crimping set. I then sealed the holes where the screws go and also where the wires go into it and then used insulation tape to wrap the whole thing up. Its going great with a lawnmower HT wire and cap now.
 

Arsytee

Seaman Apprentice
Joined
Oct 8, 2012
Messages
43
Re: Splicing a HT lead!

Excellent, thanks for that. Will get myself a new lead and have a go.
 

bodogg

Cadet
Joined
Sep 29, 2012
Messages
27
Re: Splicing a HT lead!

hi, I would strongly advise using a peice of heat shrink tube over the connection to protect it from corrosion or a possible ark,its very inexpensive and you can use a lighter to melt the tube,its better to go the extra mile than to swim back!
 
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