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Fabia MK2 front door harness AGAIN...

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Symptom, Upon locking the car I got a double pulse, from past experience I diagnoses the infamous flexible bit of the harness (pass side front door wasn't locking), poor design (should have used more flexible wires but that would have added £1 to manufacturing costs)

I replaced the D/S 3 years ago and bought 2 harnesses at the time so had a spare in the loft, now fitted and all good. I'm going to repair the removed one as a spare

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Edited by Crucian

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1 wire failure and 4 waiting to happen (as well as those we cant see under the wire insulation)

New harness replacement is now £190 🙄

Car wiring is getting thinner and thinner. They get away with thinner wire and harder thinner insulation that can cope with higher current so I reckon not so flexible and more prone to breaks. Old friend used to fit Taxi meters and some of the wiring he had to deal with was more like threads rather than cable. I suppose its a cost thing but would happily pay extra for decent cable.

Alasdair

The problem with wiring is that copper will work-harden after a lot of flexing - this causes the conductor to lose flexibility and fracture inside the insulation.

The answer is to use many more, thinner strands to make up the conductor.

Just finished rewiring my old tractor. Used classic PVC old school cable and went for higher current capacity than needed . Lots of fine strands and very flexible. 17amp standard pvc is 2mmsq copper and 16.5amp thin wall is 1mmsq copper so half the thickness of copper.

Alasdair

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