Bulkhead wire size

[Darren]

Hey guys.
Does anybody know the 2 ( or possibly 3) different gauge sizes of wires going through the bulkhead connector (1968 barracuda383s)?
I'm purchasing a new bulkhead connector and a few male and female connectors incase I have to replace a few, the website I'm ordering from has 3 or 4 different connector sizes.
Thanks advance

 

[Mattax]

You're talking the metal terminals?
It depends on which connector your replacing.
AFAIK Chrysler used SAE 12 ga for the alternator output, although it some point IIRC it wsa bumped to 10 ga for standand option,
Most everything else was SAE 14, 16 and 18 gage. No 20 gage in the 60s.

However, the commercial F crimp terminal sizing seems to be based on typical AWG sizes and insulation. So in my experience its good to have a few options in case it seems like The crimp is loose.
This will give you an idea of what's out there for us.
Sources for Chrysler type wire terminals

 

[4spdragtop]

Heres pic of schematic for bh connector. This is for 67 cuda. The dash harness. Theres quite a few different sizes. Basically from 12-18.

 

[Dana67Dart]

You may also need double wire terminals, look at the factory wiring diagram some if not all years have the wire size along with the color.


See post 3 above

Steve you beat me to it!

The proper crimpers are a must. Don't go cheap there.

 

[Darren]

You're talking the metal terminals?
It depends on which connector your replacing.
AFAIK Chrysler used SAE 12 ga for the alternator output, although it some point IIRC it wsa bumped to 10 ga for standand option,
Most everything else was SAE 14, 16 and 18 gage. No 20 gage in the 60s.

However, the commercial F crimp terminal sizing seems to be based on typical AWG sizes and insulation. So in my experience its good to have a few options in case it seems like The crimp is loose.
This will give you an idea of what's out there for us.
Sources for Chrysler type wire terminals

Yes the metal connectors
Thanks Mattax for the info , definitely helps

 

[Darren]

Heres pic of schematic for bh connector. This is for 67 cuda. The dash harness. Theres quite a few different sizes. Basically from 12-18.

View attachment 1715737208

View attachment 1715737209

Thats Great..Thanks Steve..

 

[Mattax]

The '68 bulkhead wiring is a little different than '67.
Get yourself a shop manual.
Here's a pdf version of the factory wiring diagram by @1969383S
https://www.forabodiesonly.com/mopar/attachments/68-barracuda-factory-wiring-rev-2-pdf.1715189875/
He may have updated it since 2018 but the bulkhead is AFAIK 100% correct.
For 67 the wiper connector shows only one of several options. Maybe by '68 that was fixed. I don't have a '68 (anymore).

 

[4spdragtop]

I got a fair bit of wiring I bought and a couple harnesses(1 is a 68 cuda) as I redo our 67 dash harness. Some wiring is the odd colored stuff(pink purple orange) I have lots of extras so if you need anything, lemme know.

 

[Darren]

I got a fair bit of wiring I bought and a couple harnesses(1 is a 68 cuda) as I redo our 67 dash harness. Some wiring is the odd colored stuff(pink purple orange) I have lots of extras so if you need anything, lemme know.

View attachment 1715737225

View attachment 1715737226

Nice Steve. I love that your keeping everything original color.. the future owner of your cars are really gonna appreciate that.
Thanks.

 

[nothingbutdarts]

Bringing up an old thread since it is kind of what I am asking about. I was wondering if anyone has tried to remove the fusible link connector from out of this connector and not damaging the connector or the plastic plug? As you can see in the pictures, both the fusible link wire & the other 10 gauge power wire feed have what looks like extra rubber/insulation going into the plastic connector.
I am looking to pull them both out of the plastic connector without damaging the wire or the terminal end so I can use the wire in a different plastic connector
Thank You!

 

[Scody21]

Bringing up an old thread since it is kind of what I am asking about. I was wondering if anyone has tried to remove the fusible link connector from out of this connector and not damaging the connector or the plastic plug? As you can see in the pictures, both the fusible link wire & the other 10 gauge power wire feed have what looks like extra rubber/insulation going into the plastic connector.
I am looking to pull them both out of the plastic connector without damaging the wire or the terminal end so I can use the wire in a different plastic connector
Thank You!

View attachment 1715951501

View attachment 1715951502

View attachment 1715951503

Yes, need a small thin flathead screw driver. There is a tab on one side of the side of the wire connector holding it into the plug. Have to go from the front side and gently push the tab

 

[67Dart273]

If it won't pull out it's because it's heat damaged

 

[Mattax]

I am looking to pull them both out of the plastic connector without damaging the wire or the terminal end

and more here

the other 10 gauge power wire feed have what looks like extra rubber/insulation going into the plastic connector.

Critical terminals got the rubber seal. The downside is not as easy to disapate heat.
Not many 10 ga wires used besides battery to starter relay. Late models may have had 10 ga on the alternator output to main splice (R6). Special options excepted.

 

[nothingbutdarts]

I got both of the ones out I wanted!
Thanks All!!!

 

[RioGrandMan]

Looking to redo my engine harness for my 66 bcuda either from scratch myself or with a year one m&h harness with a few mods to not overheat and burn up the bulkhead connector. Any tips, tricks, sources for engine compartment connectors etc?

All input appreciated

 

[4spdragtop]

Skip Year None, Van's Auto and others sell M&H.
Do a search there's a TON of info on wiring. I made dash harness for our 67 cuda.

Looking to redo my engine harness for my 66 bcuda either from scratch myself or with a year one m&h harness with a few mods to not overheat and burn up the bulkhead connector. Any tips, tricks, sources for engine compartment connectors etc?

All input appreciated

 

[Mattax]

Add up all of the loads that will run at the same time. This wll be the maximum steady draw on the alternator when the engine is running. Then figure which if any besides ignition and alternator will be on at the same time as the battery is charging. Battery charging is a variable but a big one. Finally add up all of the loads that will run on battery (engine off). Then you can figure the wire sizes and the connectors for the main feeds. After that figure the indivudal circuits the same way. The factory wiring strategy is great in that it is simple and straightforward for running an engine and basic electrical needs for driving. It is not a strategy which will work well with additional electric loads.