All Day Dan

My Feedback: (5)

Are there any assembly instructions available for the Briggs and Stratton rubber spark plug boot and terminal? I need to know the proper lengths to cut the wires and the crimping techniques required if any. Please refrain from any comments about how these compare to the metal caps. I am well aware of both. I just need to know how to assemble these. Thanks guys. Dan.

http://www.amazon.com/gp/product/B00...pf_rd_i=507846

wesaysoracing

when i had to make my own plug wires i stripped about 1/2 inch of insulation away folded the core back over so it is trapped between the insulation and brass terminal, the insulation ends just past the crimp zone , the wire strippers /crimper i have has a plug terminal crimping place on it

All Day Dan

My Feedback: (5)

Thanks wesaysoracing for the one and only post. Are all the connections a crimp connection? Can you describe the crimping tool a little more. Does it have a part number? Do the crimps have a specific diameter? Since the crimping is done on the terminal, is the terminal just pushed inside the boot? Can it be removed from the boot? Thanks again, dan.

Tired Old Man

My Feedback: (1)

Boy, the rubber boot, brass terminal assembly concept takes me back a few years.

The high tension wire only needs to make a firm contact with the brass terminal. That has always left a little bit of room for personal technique. With the wires I used to do the wire was pushed through the boot until there was more than enough sticking out the plug end of the boot to allow crimping the high tension lead to the wire. The the brass terminal was pushed/pulled back into the boot until it bottomed at the top of the cap. If there was a need the terminal could be pushed back out of the boot later. That changed with the advent of molded plug wires.

All Day Dan

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Good information TOM. Thanks for the input. Dan.

All Day Dan

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TOM and wesaysoracing, I dissected a boot on an old CH ignition. The terminal was crimped to the insulation around the wire with no contact to the wire. Is that the way it's done? That means that the high voltage jumps across the insulation to the terminal. Dan.

Antique

My Feedback: (4)

The terminal has or had a sharp triangle point bent 90 degrees that contacted the inner core of the spark plug wire...

Tired Old Man

My Feedback: (1)

Pretty close to the way things were done back when we had to make up our own wires for race cars.

All Day Dan

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Antique, this is what the terminal in the boot looks like. There is no provision for a penetrating tab.
http://www.etco.com/item.php?sku=09765&l=e
wesaysoracing bends back some of the core and clamps it against the rubber coat under the crimp, I think. It doesn't look like that was done either since the core is cut back within the insulation. Maybe the this thing was a botch job that was done all wrong in the first place after CH shipped the module and some one tried to make a repair. Dan.

All Day Dan

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Here's a good link. Dan.
http://www.circletrack.com/enginetec...tallation.html

Tired Old Man

My Feedback: (1)

Sounds like you had a botch job. The fold back method works fine if that's all you have to work with. The tension lead only needs to make contact with the terminal and how that is done is pretty much irrelevant if the terminal connectivity remains solid. Now if you like a professional installation the crimping tool makes for the finish touch.

wesaysoracing

if i can figure out how to post a pic i will take one of the crimpers

bcchi

I would guess your ignition has a resistor spark plug wire.Way back when we used a resistor plug wire we used a U shaped wire that was inserted into the resistor core and under the spark plug terminal and crimped togeather someone has lost the little wire.
BCCHI

All Day Dan

My Feedback: (5)

It's good to hear from you Bill. Can that reistor wire be bent back to get crimped under the terminal? If not I can insert another piece of wire. Is it that easy? Dan.

wesaysoracing

yes it was resistor wire we would buy it by the spool , the boots and terminals by the box and we had to make our own wires the crimpers are blue point pwc-13

All Day Dan

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Thank you, Dan.

wesaysoracing

the core looks like a carbon fiber strand and it will flex back over

All Day Dan

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OK. I'll give that a try. I'll shop around for a suitable boot and terminal. Dan.

wesaysoracing

we bought ours from napa

spaceworm

Do they still make Essex Magwire? That is what I used to make replacement ignition leads.

captinjohn

See if you can find a bakelite boot... the sparkplug end will screw right onto the wire end. The boot has what looks like a wood screw in where the wire goes. You can add a dab of silicone rubber/sealant to make a even better seal/bond. Capt,n

All Day Dan

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Bakelite? Can you still get things in Bakelite? Thanks for the tip. Dan.

All Day Dan

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wesaysoracing, Here's a cross section of the Belden high voltage cable. The wire inner conductor is to be exposed about a half an inch and bent back for crimping over the Belden jacket under the spark plug terminal. Right?

All Day Dan

My Feedback: (5)

Bill, You were right. This ignition module was assembled with that resistive core wire. It was not a solid wire. I took a piece of bare copper wire and sharpened one end. I bent it into a "U" shape with 1/4 inch going into the soft core and 1/2 inch on the black jacket. I had to reuse the original ETCO terminal because none of the lawn mower shops had anything decent enough for our kind of use. I got it all together with a new boot and it works like a charm. Using the CH ignition tester it draws 30ma at idle and 350ma when it is sparking. Bill, I have a couple of questions for you. I hope you're still tuned in. Do you know what the part number of the terminal is? I do believe it's an ETCO. I could be wrong. Also, what is the frequency of the spark generated with the tester? Thanks a lot. And thank you to all the guys that posted. They were a big help. Dan.

GreaTOne_65

Hey, Bill. I don't want to be a bother, but I'm in need of Bosch spark plug cap. You used to sell them, and I have used up the ones I bought from you. Can you give me a source for them?

Thanks,
Dale