Improper and unsafe car electrical wiring

Here are some examples of improper and unsafe automotive electrical wiring practices:

1) This example shows electrical tape used, twisted wire connection, and gauge transfer:

electrical tape, twisted connection, gauge transfer


Lessons to be learned:

a) Never use electrical tape with electrical wiring. Electrical tape always peels off, and becomes brittle over a longer time. To properly secure wire, use heatshrink. If you can't use insulated crimp connections.

b) Never connect wire together by twisting it together. Always solder wire together. If you cannot, then use crimp connections.

c) Never connect two different metals together (copper to tinned wire, etc). Do not connect two wires of different color. This would cause galvanic corrosion, and the connection will fail.

d) Never transfer a thick, heavy gauge wire to a thinner, higher-gauge wire. If too much current flows, the thinner wire will overheat, melt, and catch on fire before the fuse trips (the fuse is designed for the amperage of the thicker original wire).


2) This example shows exposed wire, which will short either to other wires or to the chassis:

exposed wire and electrical tape


3) Piecing together of sections of wire must never be done, as it was done here:

piecing together of wire



Here are some better practices. The wire ends are isolated, and loose wire is secured with tie wraps.


loose wire tie-wrapped and isolated


wire tie-wrapped and end isolated

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Page last modified 05-Feb-17 19:55:47 EST
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