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Stupid Plug Wire Question....

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  • Stupid Plug Wire Question....

    As some of you know, I've had issues on my car of keeping it from burning plug wires. I've tried various fiberglass sleeves, wire routing, etc. to try and find a long term solution. My latest attempt involved using this Cool Tape and wrapping areas on my plug wires that were historically having the most problems. I figured this combined with the normal fiberglass sleeves might offer a final solution.

    The last time I dug into it, I ended up rerouting the wires underneath the passenger side header to keep it away from the downpipe as much as possible. I ran it for a few months like this,but eventually found a couple wires that were still catching some heat and crisping the wires where they came in close proximity to the header. I didn't use any Cool Tape this time, but crisped some wires even though I rerouted them.

    I built a couple more wires and this time tried placing the Cool Tape on the wire where they had burned. I ran it this way for a couple of months and once again started noticing a miss.

    Today I pulled them all out to inspect them, but they were all in good condition. I figured while I had them out, I'd go overkill on them and wrap the full length of the plug wire with the Cool Tape.

    I fired it back up and it's running like total crap. My question is does this fiberglass reinforced aluminum tape cause problems for the plug wires? I'm starting to think that although it protected the wires from burning the last time, that IT was the cause of the miss, especially now that I've applied MORE of it and the problem seems even worse.

    Maybe I'm a moron, but I hadn't considered the aluminum might be causing some electrical anomolies in the signal through the plug wire. Is this a possiblity? I guess I need to try to do some overkill fiberglass sleeves without the aluminum in the equation to know for sure. Anyone have any experience using this kinda tape on plug wires??


  • #2
    I wanna know why your headers are radiating enough heat to crispy fry wires that aren't touching the header. I have fiberglass sleeves on mine right next to a turbo and they are fine. What wires, do your headers glow?
    89 dove grey lx, turbo blowthrough

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    • #3
      They don't glow to my knowledge, but this has been an ongoing issue. The tune is done through an SCT chip and it was tuned by HPP. I just bought a IR thermometer gun and plan on trying to get some data on that subject soon. Moroso Ultra 40's.

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      • #4
        Both headers will definitely glow- very short amounts of time, but they will glow. Especially down near their collectors and near the merge.

        My best luck came with a simple aluminum shield between the plug wire and offending hot part. One side of the shield will read 700*++ and the 'cool' side will be 300*.

        FWIW, if you wrap the plug wires tight - there's no air gap and they are still prone to burning. My other solution/suggestion would be to use the thermotec heat sleeves. I always use the 2" one and cut it lenght wise. Once I do that, use stainless safety wire to refasten it.

        sometimes, it's necesary to do both steps together..

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