Rally dash redo

Rally dash redo

Thanks Matt for the link. Good read!
I removed the yellow door switch wire from the harness in one piece. It appears in good shape other than the clipped ends. A couple small spots discoloured, not sure if from heat or not? They're not physically melted. I have proper new terminals and yellow wire, so I may make a new one anyway. My new iwiss crimper dosent crimp very well. I have to order a new one.
Thanks for the offer on connectors, I should be good.
Were the door switch ends bullets?

Mattax said
Thanks to @67Dart273 for warning that sometimes Chrysler type and Packard 56 terminals don't fit in the connector cavities meant for the other.
That's exactly what happened today when replacing the Packard 56 terminal shown above with the Chrysler style.

Photo1. Packard 56 terminal poorly crimped to the field wire. (repop engine harness)
Wire crimp seperates the strands instead of compressing them. Possibly the terminal was for 14-16 gage wire, and the wire is 18 gage.
Second crimp is on wires instead of insulation and too big to grip.
View attachment 1715267344

Photo 2. Yazaki terminal similar to Chrysler style installed.
View attachment 1715267345

However the 56 connector would not lock solidly onto the new terminal. View attachment 1715267347

Photo 3. Original 1967 Chrysler connector on left; Packard 56 connector on right. Not the same.
View attachment 1715267346
The new Yazaki Chrysler style terminal locked in solidly to original 1967 connector. :)

Mattax said
I'd take it back to where it seems good and a splice will be in a relatively straight run. I used to lean toward soldering the splices but for this situation I'd lean toward an open barrel crimp. That way it will have more flexibility.
Like Del shows here:Inline wiring splice clips........from the Dodge RAM service manual

Mattax said
Steve - if you just need one or two of those terminals, lemme know. Unfortunaley didn't get many of the splice ones. May use a few on my repair and '60 amp' wiring mod. Today I got the rest of the parts to get it done.