2 4 0 T U R B O . C O M
D A V E ' S   V O L V O   P A G E
Volvo Harness Parts
Connectors, Terminals, Etc.


      UPDATED: April 6, 2018           CONTACT          SHIPPING       VIEW CART
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C l i c k   a   L i n k   B e l o w
Sealed or Waterproof FUSE Holders BOSCH EFI PLUGS 2-Pole and 3-Pole
VOLVO 2-Pole, 3-Pole, 4-Pole and 8-Pole Sealed  HarnessPlug Housings Wire Pigtails for VOLVO Harness Plugs
5-Pole RELAY Plugs
.250 inch (6.3 mm) Terminals for Relay Plugs
6-Pole Fuel Pump Relay Plug
VOLVO Headlight STEP RELAY Plug Housings
Headlight Harness Plugs .312 inch .312 inch Terminals for Headlight Plugs
Large Terminals .375 inch (9.5 mm) OVERCRIMPS for using LARGE Wire with Not-So-Large Terminals
Bullet Plugs and Terminals (non-sealed 3.5 mm VOLVO under-dash type) BLACK VINYL HARNESS TUBING Sizes 1/8 to 1 inch Diameter
Helpful Instructions: PROPER USE OF A CRIMPER Adding additional purchase or shipping payment


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Volvo 240 Fuse HolderSEALED FUSE HOLDER  --  Assembled or Unassembled Kit
Sealed Fuse Holder Kit
<<<
This waterproof fuse holder uses a standard blade fuse (ATO/ATC type), same as original on a 240 fender fuse holder pictured at right >>>).

  
If your 240 has ever had a dirty or corroded LH Injection fuse then a sealed fuse holder like this will keep that from happening. 






       

Available in three kit types:
Kit #1: Fully assembled with 12 gauge wire (as shown above), 36 inch loop wire, with 25A fuse

$12.00 plus shipping.  IN STOCK

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Kit #2: UNASSEMBLED kit that you may assemble and install on your car (25A fuse included).  
This unassembled kit includes the fuse, waterproof housing, cap, and crimp terminal inserts. Use your own 12 or 14 gauge wire (Volvo used 14 gauge originally).  Assembly is easier than you think.

$8.00 plus shipping.  IN STOCK

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Kit #3: Fully assembled fuse holder installed by us on a new harness (with new harness purchase only) (25A fuse included). 

$8.00 plus harness purchase. 
IN STOCK

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SEALED FUSE HOLDER  --  Big 10 Gauge Wire
Sealed Fuse Holder KitThis sealed, water-resistant, in-line fuse holder features big 10 gauge wire leads (12 inch wire loop). It uses a standard blade fuse (ATO/ATC type).   If youre installing an electric primary cooling fan or any other high current device and need a large wire fuse holder, then this will do well.  40A fuse included.









     
$5.00 each plus shipping.  IN STOCK

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Bosch Style Fuel Injection (EFI) Connector Plugs, Parts

2-Pole Female EFI Plug Housings
Female EFI Terminal Inserts
2-Pole MALE EFI Plug Housings MALE EFI Terminal Inserts
3-Pole Female EFI Plug Housings
Blue EFI Plug Seals

Fuel Injection 2-Pole PlugFuel Injection 2-Pole PlugBosch style Female EFI 2-Pole Plug Housing.
Used for Fuel Injectors or Sensors
(AKA: EV1 housing).
Connector Housing Only. Terminal inserts NOT included
(terminals are available below).
 
.







  
$5.00 each plus shipping.  IN STOCK

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EFI Crimp TerminalsEFI Crimp TerminalsEFI Female Crimp Terminal Insert.
For Female EFI Plug Housings.

These terminals fit the above Female EFI plug housing and are typically crimped onto 14-18 gauge wire.  These are also the correct fitting terminals for many other Volvo engine connector plugs, such as the MAF (Mass Air Meter), Throttle Position Sensor and many engine sensors.





    
$0.45 each plus shipping.  IN STOCK

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Fuel Injection Male 2-Pole PlugBosch style MALE 2-pole EFI Type Plug Housing. 
(AKA: EV1 housing)
Terminal Inserts available below.





   
$5.00 each plus shipping.  IN STOCK

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EFI Male Crimp Terminal Insert.
For Male EFI Plug Housings.

These terminals fit the above Male EFI connector plug housing and are typically crimped onto 14-18 gauge wire. 





    
$0.45 each plus shipping.  IN STOCK

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Bosch style Female 3-pole EFI type Sensor Connector Plug Housing.  Housing only.  Fits Volvo TPS, some Idle Valves, Crank Position Sensor.
Crimp Terminal Insert NOT included (available below).





   
$5.00 each plus shipping.  IN STOCK

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  .


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EFI Crimp TerminalsEFI Crimp TerminalsEFI Female Crimp Terminal Insert.
For Female EFI Plug Housings.

These terminals fit the above Female EFI plug housing and are typically crimped onto 14-18 gauge wire.  These are also the correct fitting terminals for many other Volvo engine connector plugs, such as the MAF (Mass Air Meter), Throttle Position Sensor and many engine sensors.




    
$0.45 each plus shipping.  IN STOCK

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Silicone Seals for above EFI Connector Housings.
These seals fit into the back of these EFI plug housings and will seal the wire going into the back side from moisture.  Using these seals is a good idea if you will not be using a rubber boot.  They are generally not needed if you are using a rubber boot, but still may be used for extra sealing.  Two are needed for a 2-pole male or female plug housing.





  
$0.15 each plus shipping.  IN STOCK

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VOLVO Sealed Plugs and
Bullet Terminal Inserts for Volvo Engine Harnesses

8-Pole Female Volvo Plugs
8-Pole MALE Volvo Plugs
2-Pole Female Volvo Plugs
2-Pole MALE Volvo Plugs
3-Pole Female Volvo Plugs
3-Pole MALE Volvo Plugs
4-Pole Female Volvo Plugs
4-Pole MALE Volvo Plugs
Female Bullet Pigtails
MALE Bullet Pigtails
1-Pole Female Plug with Pigtail


A helpful guide for 240 firewall harness loom repairs may be found at the below link: 

http://www.davebarton.com/pdf/harness_firewall_loom_repair_240t.pdf

OPENING VOLVO SEALED PLUG HOUSINGS
Use a small (micro) screwdriver or a pick to pry the back door open.  It will not require much effort.  When closing, it will snap into place.


Click photo for larger image
FEMALE 8-Pole Plug

Genuine Volvo FEMALE 8-pole sealed bullet connector housing.
Commonly found on Volvo engine harnesses. Many older original plugs were gray. This is now black. These are the later type and are slightly different from the early type found on late-1970s or early 1980s Volvos. 

This is the housing only. These use the below sealed female bullet terminal inserts for a weatherproof connection: CLICK HERE

$6.00 each plus shipping.  IN STOCK

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MALE 8-Pole Plug

Genuine Volvo MALE 8-pole sealed bullet connector housing.
For common Volvo engine harnesses using an 8-pole firewall or fender plug.  Black plastic. These are the later type and are slightly different from the early type found on late-1970s or early 1980s Volvos. 

This is the housing only. These use the below sealed male bullet terminal inserts for a weatherproof connection: CLICK HERE

$6.00 each plus shipping.  IN STOCK

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FEMALE 2-Pole Plug

Genuine Volvo FEMALE 2-pole sealed bullet connector housing.
For common Volvo engine harnesses using a 2-pole female plug for some engine sensors, rear differential speed sensor or sometimes a fender or firewall plug.  These use the below female 3.5 mm sealed bullet terminal inserts for a weatherproof connection. 

This is the housing only. The female bullet terminal insert pigtails are sold separately below: CLICK HERE
ORIGINAL VOLVO PART marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).

$6.00 each plus shipping.  IN STOCK

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MALE 2-Pole Plug

Genuine Volvo MALE 2-pole sealed bullet connector housing.
For common Volvo engine harnesses.  These use the below male 3.5 mm sealed bullet terminal inserts for a weatherproof connection.  This is the housing only. The male bullet terminal insert pigtails are sold separately below: CLICK HERE

$4.00 each plus shipping.  IN STOCK

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Genuine Volvo FEMALE 3-pole sealed bullet connector housing.
For common Volvo engine harnesses using a 3-pole plug for a fender or firewall plug or other device.  These use the below female 3.5 mm bullet terminal inserts for a weatherproof connection.
These have been out of production from Volvo for a few years, but they are still available for a limited time.
This is the housing only. The female bullet terminal insert pigtails are sold separately below: CLICK HERE.

$6.00 each plus shipping.  IN STOCK

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Genuine Volvo MALE 3-pole sealed bullet connector housing for common Volvo engine harnesses using a 3-pole plug for a fender or firewall plug or other device.  These use the below male 3.5 mm bullet terminal inserts for a weatherproof connection.
These have been out of production from Volvo for a few years, but they are still available for a limited time.
This is the housing only. The male bullet terminal insert pigtails are sold separately below: CLICK HERE.

$6.00 each plus shipping.  IN STOCK

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FEMALE

Genuine Volvo FEMALE 4-pole sealed bullet connector housing
This is the housing only.
The female bullet terminal insert pigtails are sold separately below: CLICK HERE.
ORIGINAL VOLVO PART marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).

COMMON USES:
740/940 models: Radio Noise Suppression Relay Plug.
240 models: Cooling Fan Relay Plug.
 


These have been out of production from Volvo for a few years, but they are still available for a limited time.


$6.00 each plus shipping.  IN STOCK

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MALE

Genuine Volvo MALE 4-pole sealed bullet connector housing for some Volvo engine harnesses and connector locations. This is the MALE opposite of the female 4-pole plug directly above.  These have been out of production from Volvo for a few years, but they are still available for a limited time. 
This is the housing only. The female bullet terminal insert pigtails are sold separately below: CLICK HERE.

$6.00 each plus shipping.  IN STOCK

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FEMALE

FEMALE 3.5 mm WIRE PIGTAILS: Female bullet wire pigtail inserts for all above Volvo sealed connector plug housings.  Each pigtail comes with approximately 24 inches (60 cm) of wire.  Several wire colors are available.  (These are inserts with wire only. Pictured connector plug housing NOT included)

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge). If you need a larger wire, the Fat wire colors below may help.
Fat Yellow/Blue: 2.0 mm² (metric)
, which is comparable to approximately AWG 14 (14 gauge). 
Fat Red Black or Blue: A fatter red, black or blue wire is also available in 2.5 mm² (metric), which is comparable to approximately AWG 13 (13 gauge). That is the fattest wire available for these pigtails.

If you need a lot of one color you might email first. I don't always keep a large quantity of each color in stock.  Occasional I run out and it can take a few weeks to get more.

  
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red, Black or Blue 2.5 mm² wire.
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MALE

MALE 3.5 mm WIRE PIGTAILS: Male bullet terminal pigtail inserts for all above Volvo sealed connector plug housings.  Each pigtail comes with approximately 24 inches (60 cm) of wire. Several wire colors are available.  (These are inserts with wire only. Pictured connector plug housing NOT included)

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge).
If you need a larger wire, you may choose the Fat Yellow/Blue, which has a 50% fatter wire size: 1.5 mm² (metric size), which is comparable to approximately AWG 14-15 (14 gauge). 

If you need a lot of one color you might email first. I don't always keep a large quantity of each color in stock.  Occasional I run out and it can take a few weeks to get more.





  
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red, Black or Blue 2.5 mm² wire.
IN STOCK

Order Quantity: Select Color:

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Click photo for larger image
FEMALE

Comes assembled as pictured.
Special FEMALE 1-POLE Sealed Bullet Plug Housing with terminal insert and wire pigtail:
Female bullet terminal pigtail with pictured Volvo 1-pole plug housing. This comes FULLY ASSEMBLED. 
Housing is an ORIGINAL VOLVO PART marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).

<<< If you're looking for the correct sealed connectors for this Volvo (Bosch) fuel pump, or for the Oil Pressure Sender on B230F/FT engines, then these are the correct ones.

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge). If you need a larger wire, the Fat wire colors below may help.
Fat Yellow/Blue: 2.0 mm² (metric)
, which is comparable to approximately AWG 14 (14 gauge). 
Fat Red Black or Blue: A fatter red, black or blue wire is also available in 2.5 mm² (metric), which is comparable to approximately AWG 13 (13 gauge). That is the fattest wire available for these pigtails.



   
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red, Black or Blue 2.5 mm² wire. 
IN STOCK


Order Quantity: Select Color:

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Relay Plugs and Terminals

5-Pole Relay Plug
5-Pole Interlocking Relay Plugs
6-Pole Fuel Relay Plug
240 Headlight Step Relay Plugs
.250 inch (6.3 mm) Plug Terminals


5-Pole Female RELAY PLUG
Fits all standard 4 or 5-pole mini relays. Uses .250 inch (6.3 mm) female locking terminals (offered below).


Click here for tips on removing wire connector inserts from these sockets.

IN STOCK
 $2.00 each, or buy 2 or more for $1.50 each.


  
   
Order Quantity ($2.00 for 1):


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5-Pole Interlocking RELAY PLUG SOCKET
Click here for tips on removing wire connector inserts from these sockets.






  

IN STOCK
 $2.50 ea.
or buy 2 or more for $2.00 ea.

    
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Order Quantity (2 or more for $2.00 ea.):






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6-Pole Female RELAY PLUG
Fits all Volvo 6-pole fuel pump relays using this plug. Uses .250 inch (6.3 mm) female locking terminals (offered below).

Correct fuel pump relay plug replacement for all 240 models with fuel injection (any and all mechanical or electronic fuel injection).

Click here for tips on removing wire terminal inserts from these sockets.




   


IN STOCK
 $3.00 each.

 

6-pole Relay Plug Socket. Order Quantity:



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Genuine Volvo HEADLIGHT RELAY PLUGS
<<< For all Volvo headlight step relays.
Genuine Volvo replacements in case yours are melted, damaged, etc.
Uses .250 inch (6.3 mm) female locking terminals (offered below).

Click here for tips on removing wire terminal inserts from these sockets.





Two types:
3-pole plug: $3.00 each In Stock
5-pole plug: $3.00 each In Stock

3-Pole Plug ORDER HERE:
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5-Pole Plug ORDER HERE:
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 .250 inch (6.3 mm) FEMALE terminals.  For all above relay plug housings.
Two wire sizes available:
SMALL: 14-18 gauge wire recommended. $0.40 each





LARGE: 10-12 gauge wire recommended. $0.50 each


NOTE: The LARGE terminals will normally accept a maximum of 10 gauge wire, however it is possible to use it with larger 8 gauge cable. This is done using a large overcrimp. See pics at right >>>
Overcrimps can be found further below, or CLICK HERE

IN STOCK

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Quantity discounts available on orders of 50 or more of either size: $0.25 each
Order Quantity: Select Size:

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.250 inch (6.3 mm) Plugs and Terminals

1-Pole .250 inch Female Plug WHITE
1-Pole .250 inch Female Plug BLACK
.250 inch Female Crimp Terminals
Special .250 inch "Piggybacks"
.250 inch MALE Crimp Terminals 1-Pole .250 inch MALE Plug WHITE
1-Pole .250 inch MALE Plug BLACK 2-Pole .250 inch Female Plug
2-Pole .250 inch MALE Plug 4-Pole .250 inch Female Plug
4-Pole .250 inch MALE Plug 6-Pole .250 inch Female Plug
6-Pole .250 inch MALE Plug 8-Pole .250 inch Female Plug
8-Pole .250 inch MALE Plug

Click photo for larger image
1-Pole Female Insulator (white) for all .250 inch (6.3 mm) female terminals.
As shown on left, insulator only. Fits either small or large wire terminal.  $0.30 ea.e
Quantity Discount:  20% discount for 10 or more:   $0.24 ea.
Quantity Discount:  30% discount for 20 or more:   $0.21 ea.
Discounts are calulated automatically when you order.


   

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Click photo for larger image
1-Pole Female Insulator (BLACK) for all .250 inch (6.3 mm) female terminals.
As shown on left, insulator only. Fits either small or large wire terminal.  $0.60 ea.
Quantity Discount:  20% discount for 10 or more:   $0.48 ea.
Quantity Discount:  30% discount for 20 or more:   $0.42 ea.
Discounts are calculated automatically when you order.
bos0


    ,30e
ORDER HERE: (1-Pole Insulator BLACK for all .250 inch FEMALE Terminals) Order Quantity:


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 .250 inch (6.3 mm) FEMALE terminals.  For all above relay plug housings.
Two wire sizes available:
SMALL: 14-18 gauge wire recommended. $0.40 each





LARGE: 10-12 gauge wire recommended. $0.50 each


NOTE: The LARGE terminals will normally accept a maximum of 10 gauge wire, however it is possible to use it with larger 8 gauge cable. This is done using a large overcrimp. See pics at right >>>
Overcrimps can be found further below, or CLICK HERE

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Quantity discounts available on orders of 50 or more of either size: $0.25 each
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Click photo for larger image
.250 inch (6.3 mm) Special Female Terminal with Male "Piggyback"
Small: for 18-22 gauge wire.   $0.30 ea.
Large: for 10-16 gauge wire.   $0.40 ea.
Hard to find. Commonly used on 240 fuse panel    (p h o t o   t o   r i g h t  > > >)






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Click photo for larger image
.250 inch (6.3 mm) male terminal.
Available in TWO wire sizes. 
SMALL: For 14-18 gauge wire.   $0.40 ea.
LARGE: For 10-14 gauge wire.   $0.50 ea.


   




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Click photo for larger image
1-Pole Male Insulator (white) for above .250 inch (6.3 mm) male terminal.
As shown on left, INSULATOR ONLY.  
$0.40 ea.




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Click photo for larger image
1-Pole Male Insulator (BLACK) for above .250 inch (6.3 mm) male terminal.
As shown on left, INSULATOR ONLY.  
$0.40 ea.



    


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Click photo for larger image
2-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.  
$0.80 ea.




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Click photo for larger image
2-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only.
$0.80 ea.




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4-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.
$1.40 ea.   




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4-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only. 
$1.40 ea.   




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6-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only. 
$3.00 ea.   




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6-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only. 
$3.00 ea.   




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8-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.  
$3.00 ea.    




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Click photo for larger image
8-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only.  
$3.00 ea. 




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Headlight Plugs and Terminals

3-Pole "Flag" Headlight Plug
.312 inch "Flag" Terminal
3-Pole Straight Plug
.312 inch Straight Terminal (Small)
.312 inch Straight Terminal (Large)


Click photo for larger image


Headlight Plug Housing (3-poles).
Fits Standard or H1 or H4 type (also 9003).
Uses .312 inch (7.9 mm) FLAG terminals (shown below).

This is a standard (flag) plug for all H1 and H4 headlight bulbs. It uses the .312 inch (7.9 mm) 90 degree (flag) terminal shown below.  Use this plug to repair or build your own new headlight harness.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



$1.50 each,    IN STOCK 


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.312 inch (7.9 mm) Female Locking Flag Terminal for above Headlight Plug.
90 degree (flag) type terminal. Hard to find terminal for wire size 12-16 gauge. 12 gauge will fit if you're careful. It takes a little finesse. No flag terminal of this type will hold larger wire than this one.  Has correct tab for locking into place in a flag headlight plug (above).

This terminal will not accept an overcrimp. 
If you want to use big 10 gauge wire for your headlights, I recommend changing to the straight type plug below.



$0.45 each,   IN STOCK 


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Click photo for larger image


Headlight Plug Housing (3-poles).
Fits Standard or H1 or H4 type (also 9003).
Uses .312" STRAIGHT female terminals (below).

This is a standard plug for all standard headlights or H1 / H4 headlight bulbs. It uses the .312 inch (7.9 mm) straight terminal shown below.  Use this plug to repair or build your own new headlight harness.

If you want to use big 10 gauge wire for your headlight relay harness, I recommend changing to this straight type plug. Scroll down for more.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



PRICE: $1.75 each.   IN STOCK 


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Click photo for larger image



.312" (7.9 mm) Female Locking Terminal for above STRAIGHT Headlight Plug.
Fits 12-16 AWG wire.

Straight type, hard to find terminal for large wire size 12-16 gauge.  Fits the black headlight plug housing above. Has correct tab for locking into place.

<<< Do you want to use this terminal with big 10 gauge wire to make an ultimate headlight harness?  Use a small OVERCRIMP (see photo). The OVERCRIMPS are available a bit further below or CLICK HERE.





.312 Female Straight Terminal 12-16 AWG
PRICE:  $0.65 each.   IN STOCK

 

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Click photo for larger image



.312" (7.9 mm) Female Locking Terminal for above STRAIGHT Headlight Plug.
Largest Size: Fits 10-12 AWG wire.

These terminal inserts were VERY hard to find.  Fits the black straight headlight plug housing shown (same as above). Fits large wire sizes: 10 gauge wire shown in photo.  There is no other headlight terminal that will hold 10 gauge wire. 
Fits the above straight headlight plug, except for ONE PROBLEM:
These terminals lack the locking tab, which "clicks" and locks the terminal into the housing.  Without this locking tab, the terminal could be pulled out the back (which would not happen after being plugged in of course).  However, if this bothers you, a solution is to drop a blob of epoxy into the back of the housing as shown in the photo.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



.312 Female Straight Terminal for large 10 Gauge wire
PRICE:  $0.75 each.   IN STOCK

 


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.375 inch (9.5 mm) Terminals

3-Pole "Flag" Headlight Plug
.312 inch "Flag" Terminal
3-Pole Straight Plug
.312 inch Straight Terminal (Small)
.312 inch Straight Terminal (Large)


Click photo for larger image

.375" (9.5 mm) FEMALE Crimp Terminal
Hard to find large terminals for large wire sizes.
<<< TWO Wire Sizes: 10-12 gauge small (terminal on left) or 8-10 gauge large (terminal on right). 

This is the correct size to fit the large spade on a 240 wire junction box (shown on right >>>).  The Volvo junction box originally used the small 10-12 gauge terminal.


<<<
if needed, you may even use this terminal with up to 6 gauge wire?  Use a large OVERCRIMP to accomplish this.  Overcrimps are available below or CLICK HERE.


  


PRICE: $0.75 each, either size.  IN STOCK
 

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Click photo for larger image



.375" (9.5 mm) MALE Crimp Terminal
Hard to find large male terminal for large wire sizes: Fits large 8-12 gauge wire.  Using a .375 inch male and female for high-power connections is a much better choice than more common .250 inch (6.3 mm) terminals.  If you're skeptical about this, have a look at the below comparison photo.  High-power connections using a heavy amp load, such as a BIG primary cooling fan, will eventually overheat a small connection.  That will cause a future failure.  Insulating these can be done with some simple heat-shrink tubing.

 
if needed, you may even use this terminal with up to 6 gauge wire?  Use a large OVERCRIMP to accomplish this.  Overcrimps are available below or CLICK HERE.

<<< Comparison photo of .375" terminals to ordinary .250" terminals.
These large terminals provide substantially more conductor surface area for a high-load connection.


   


PRICE: $0.75 each,   IN STOCK 


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PROPER CRIMPING tools are important. 
<<< Try not to use a cheap crimper or the wrong type for the terminal you're using.  To start with, buy yourself a basic crimper at least as good as this one pictured. 
 For those of you who are curious about what crimper I use, this one at left works for 90% of my crimps for non-insulated and many insulated terminals.  Thomas & Betts model WT 112M. It runs about $45, but there are less expensive knock-offs out there. I've probably had this one for 25 years.  With some practice, this tool can create nice crimps just like a fancy tool.

<<< For a tool that's a bit more fancy, look for a ratcheting crimper that will do open barrel F type terminals.  You can spend a lot of money on one of these tools, but it you hunt carefully, you can find something like this one, which is only $31 for all that stuff.  The crimp type dies normally used for terminals on this page is the die set in the center.  The other dies might come in handy, so they would be a bonus.  I don't own this tool.  Mine was closer to $100 ten plus years ago. This one is cheap and might be worth the cost, or it might explode. You can never really tell until it's in your hands and you try it out.
HERE: https://www.amazon.com/dp/B01CVH8JNO?psc=1


Here's a good crimping guide for beginners: http://www.xj4ever.com/crimping my style.pdf





Here's a decent video showing close-up crimping action for an open barrel terminal.





Overcrimps for Large Wire



SMALL OVERCRIMP PIC





LARGE OVERCRIMP PIC


OVERCRIMPS for using Oversized Wire on Undersized Terminals
Hard to find open barrell terminal OVERCRIMPS in two sizes: Small and Large. For use when your wire is a bit oversized for the terminal.  In an ideal world, you would simply find a terminal that accepts larger wire. Try that with 8 or 10 GA wire on most available terminals.  Sometimes the fit just isn't good enough.  Adding one of these overcrimps can really be a life saver. 
Overcrimps will not fit FLAG style terminals.
Overcrimp

TWO SIZES:  
<<< SMALL OVERCRIMP
Typically works on terminals that normally allow a MAX of 12 GA wire.  This will allow the use of 10 GA wire instead. 

PRICE: $0.25 ea          IN STOCK







<<< LARGE OVERCRIMP

Typically works on terminals that normally allow a MAX of 8 or 10 GA wire.
This will allow the use of up to 6 to 8 GA wire instead. 

PRICE: $0.50 ea           IN STOCK


















ORDER HERE:

Order Quantity:       CHOOSE SMALL ($0.25) OR LARGE ($0.50):  

Quantity Discount: 10 or more.   Small: $0.20 each.   Large: $0.40 each.

Order Quantity:       CHOOSE SMALL OR LARGE:  

Quantity Discount: 50 or more.   Small: $0.15 each.   Large: $0.30 each. 
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OVERCRIMP TECHNICAL SPECS:
Small overcrimp: Brass wall thickness 0.025 inch (0.635 mm).
Length: 0.250 inch (6.35 mm).
Width: 0.220 inch (5.59 mm).
Height: 0.300 inch (7.62 mm). 
Distance between wings: 0.195 inch (4.95 mm).
Large overcrimp:
Brass wall thickness 0.030 inch (0.762 mm).
Length: 0.325 inch (8.25 mm).
Width: 0.345 inch (8.76 mm).
Height: 0.315 inch (8 mm). 
Distance between wings: 0.305 inch (7.75 mm). 

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3.5 mm Bullet Plugs and Terminals (non-sealed).
Typically used for under-dash wiring.

Click photo for larger image
4-pole Gray MALE Plug Housing
Housing only. Terminals and wire not included. For below 3.5 mm male bullet terminals.
$4.00 each.   IN STOCK
  bos0,85e


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Click photo for larger image
3.5 mm MALE Bullet Terminal. Fits above 4-pole Plug Housing
Terminal only. Plug housing not included.
$0.50 each.   
IN STOCK  b
0.12e
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Insulator for above 3.5 mm MALE Bullet Terminal.
Clear Insulator only. Terminal and wire not included.
$0.30 each.   
IN STOCK  b


os0.12e

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4-pole Blue FEMALE Plug Housing
Housing only. Terminals not included. For below 3.5 mm female bullet terminals.
$4.00 each.  
IN STOCK    bos0,1

5e


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3.5 mm FEMALE Bullet Terminal for above 4-pole Plug Housing
Terminal only.
$0.50 each.  
IN STOCK    bos0.1





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High Quality Vinyl Tubing for Wire Harness Applications.
Soft, flexible, high-temperature resistant.
Identical to Volvo OEM vinyl.
Used for vintage electrical harness restorations or custom harness construction.


  
--  MINIMUM Order for below Tubing Please:  $5.00  --
ALL SIZES IN STOCK UNLESS OTHERWISE NOTED
      SIZE I/D            INTERNAL DIMENSION                            WALL THICKNESS                                       PRICE PER FOOT
1/8 inch ID: 0.118 inch (3 mm)
Wall thickness: 0.020 inch (0.5 mm)
$0.50 per foot
(weight approx 0.1 oz/ft)
Order Quantity:  
3/16 inch ID: 0.188 inch (4.8 mm)
Wall thickness: 0.020 inch (0.5 mm)
$0.60 per foot
(
weight approx
0.12 oz/ft)
Order Quantity:  
1/4 inch ID: 0.250 inch (6.3 mm)
Wall thickness: 0.020 inch (0.5 mm)
$0.70 per foot
(
weight approx
0.18 oz/ft)
Order Quantity:  
5/16 inch ID: 0.313 inch (8.0 mm)
Wall thickness: 0.025 inch (0.63 mm)
$0.80 per foot
(
weight approx
0.25 oz/ft)
Order Quantity:  
3/8 inch ID: 0.375 inch (9.5 mm)
Wall thickness: 0.025 inch (0.63 mm)
$0.90 per foot
(
weight approx
0.32 oz/ft)
Order Quantity:  
7/16 inch ID: 0.438 inch (11.1 mm)
Wall thickness: 0.025 inch (0.63 mm)
$1.00 per foot
(
weight approx
0.39 oz/ft)
Order Quantity:  
1/2 inch ID: 0.500 inch (12.7 mm)
Wall thickness: 0.025 inch (0.63 mm)
$1.20 per foot
(
weight approx
0.45 oz/ft)
Order Quantity:  
9/16 inch ID: 0.563 inch (14.3 mm)
Wall thickness: 0.030 inch (0.76 mm)
$1.40 per foot
(
weight approx
0.63 oz/ft)
Order Quantity:  
5/8 inch ID: 0.625 inch (15.9 mm)
Wall thickness: 0.030 inch (0.76 mm)
$1.70 per foot
(
weight approx
0.82 oz/ft)
Order Quantity:  
3/4 inch ID: 0.750 inch (19.0 mm)
Wall thickness: 0.035 inch (0.89 mm)
$1.90 per foot
(
weight approx
1 oz/ft)
Order Quantity:  
7/8 inch
ID: 0.875 inch (22.2 mm) Wall thickness: 0.035 inch (0.89 mm) $2.00 per foot
(weight approx 1.1 oz/ft)
Order Quantity:  
1 inch ID: 1.00 inch (25.4 mm)
Wall thickness: 0.035 inch (0.89 mm)
CLEARANCE SALE PRICE
$1.00 per foot

(
weight approx
1.2 oz/ft)
Order Quantity:  
--  MINIMUM Order for above Tubing Please:  $5.00  --
Due to size of packaging, please use PRIORITY MAIL for all Vinyl Tubing Orders
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Volvo Relays
240 Window Scrapers
740/940 Scrapers
740 Turbo/Boost Faces
Volvo Gauge Faces
Adj Voltage Regulators
Horn Buttons
740 Odometer Repair
850 Odometer Repair
240 Odometer Repair
240 Hydraulic Clutch
Classic Auto Air AC 4 Speed Fan Controller Limited Slip Read Ends 240 Mods and Fixes
Group A Racing
Electric Fan Diagrams
Tropical Fan Clutches
Modified 240 Favorites
Side Marker Lights
SoCal Salvage Yards
Unleaded Racing Fuel
B26FT Stroker
245 Spec Page
Vacuum Diagrams
Used Stuff
240 Big Brakes
R-Sport Apparel
Prancing Moose Apparel
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