Club 80-90 Forums

Hello all.

I've removed my glow plugs and am about to replace them with a new set. I am not confident that the 'bus bar' will stay intact if I connect the first 2 difficult to reach plugs and wiggle it about to get the plugs seated. So, I'm thinking of making a replacement for the bus bar with wire and 5mm ring terminals.
What gauge wire should I use to connect all the glow plugs together? Is 65/0.30 ok? I believe it's rated to 35A.

^^^^^^
...erm...36A rated cable?

Are your nuts silver or brass? (if brass don't go out in cold weather).
Siver.....I personally would use something like 60A minimum - after all the fuse is rated at 50A.
I can't see how you would damage the bus bar anyway - you don't need to lever the plugs in with it, just use it to hold the plug in position then turn the plug. I have never damaged one using it to assist replacement.

Me new nuts are silver.

My bus bar seems a bit fragile around where the 2nd plug would go. It may snap.

Just buy a used buzz bar rather than bodging with wire.

Martin

California Dreamin wrote:Just buy a used buzz bar rather than bodging with wire.

I am hoping to IMPROVE the setup rather than bodge it.

pauly8888 wrote:

California Dreamin wrote:Just buy a used buzz bar rather than bodging with wire.

I am hoping to IMPROVE the setup rather than bodge it.

Now I am confused...how can fitting an original part be a bodge and what makes you think a few pieces of wire and 5mm ring terminals will improve on VW's own one piece buzz bar?


Martin

California Dreamin wrote:how can fitting an original part be a bodge

I was talking about your comment about bodging with the wire.

I was thinking more along the lines of providing each glow plug with a separate wire for ease of testing/removal etc.

I've looked for a new bus bar and have been unable to find one.

Oh I see....in that case I suppose it would be feasable to make up 'seperate cables' rated at say 25amps (each one drawing a max of 12amps if later quick glow type)
Obviously these wires would need connecting together at some point and that is where I see the next problem as the supply connection would need to be much more substantial (60amps).
Also....you have the additional considerations of the wire being flexible and heat resistant, making sure none were chaffing or close to hot surfaces.

Martin

Having a think about this I would be more inclined to make a new buzz bar with some maluable copper 10mm X 2mm flat bar. Insulating the bar with shrink wrap between each plugs and shaping the bar as necessary to avoid shorting.
Drilling holes where needed.
http://www.metelec.co.uk/copper-flat-bar.php" onclick="window.open(this.href);return false;

It's an idea.

Martin

California Dreamin wrote: Obviously these wires would need connecting together at some point and that is where I see the next problem as the supply connection would need to be much more substantial (60amps).

With this mod the leads Nos 2, 3 & 4 connect to No. 1 glowplug.
Number 1 is connected in the standard way.

EHT Silicon multiflex wire with 15+ amp rating should be enough. It has to be silicon to withstand the temps.

There's a bit in the wiki about it -
https://club8090.co.uk/wiki/Di ... _replacing

Titus A Duxass wrote:EHT Silicon multiflex wire with 15+ amp rating should be enough.

Cheers, that's what I was looking for.

And thanks Martin.