Two of the main design goals of the car are simplicity and lightness. Wiring harnesses can become extremely complex and because they are made of dense metals like copper, they can also become extremely heavy. The wiring harness for the average passenger car now weighs 150 kg! That’s the weight of two passengers!

The guys at RB Racing have had to deal with extreme corrosion while racing their motorcycles on the Bonneville salt flats and have written a very nice tutorial on building corrosion-resistant wiring harnesses. Some advice from these seasoned racers:

  • Use Mil-Spec connectors
  • Use circuit breakers instead of fuses
  • Use heat shrink tubing on all connections
  • Use epoxy sealant on all connections before you shrink wrap them
  • Use Mil-Spec wire (MIL-W-22759/44)
  • Use Mil-Spec twisted pair wire ( M22759/16) for all sensor wires
  • Use K4 Triple Sealed Switches
  • Use thermal wire strippers so you don’t nick the wires
  • Use Daniels crimping tools
  • Use a Daniels Contact Retention Test tool to make sure all crimps will hold
  • Use Mil-Spec (Mil-T-43435B) Lacing Cord to tie wire bundles together
  • Use a Portable Shrink Tube Thermal Printer to print out labeled shrink-wrapped labels on each wire
  • Spray Boeshield T-9 on any metal surfaces that will be exposed to corrosion


Will Martin is an energy analyst and expert on peak oil and alternative currencies. He is an MBA graduate of Cornell University, where he was a Roy H. Park Leadership Fellow and concentrated on studying sustainability in business through the school’s Center for Sustainable Global Enterprise. Prior to his MBA, Will worked in the energy industry, living in Singapore, Houston and Dubai. Will is a recipient of the 2012 “Pioneer Award” from the Association for the Study of Peak Oil and Gas (ASPO-USA). He currently works as a carbon trading commercial adviser in the San Francisco Bay Area. Will is a bitcoin enthusiast and in 2014 published the book “Anonymous Cryptocurrencies,” which became a #1 best seller in 3 Amazon categories and was the first book to be sold on a decentralized marketplace.

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