Bongo Fury

I found a broken wire(why my rear wiper wasn't working) and another one chafed a bit(Demister), in the rubber gaiter between tailgate and body. With the help of the factsheet i was able to get the end of the loom through the bodywork and into the cab so that i can tidy up and repair the wires. Just waiting till i can borrow a soldering iron.
What can i use to reinforce the cables to prevent this happening again?
Has anyone done this before, that is, removed and re-fed the cables through the cab as it was a bit of a mare to get it out and i am assuming it is gonna be even more difficult to get it back in.
I managed to get it through and retain the gaiter on the cables as it didn't look too easy to get the gaiter off.
Would it be better to get the gaiter off and feed just the wires through and replace the gaiter when it is through, or just soldier on with it in situ?
Any thoughts/tips very welcome.
Tony

If you reinforce the wires within the gaiter section then you will generate more problems, as the idea is that they twist within the horizontal section rather than bend. Where about did the break and chaffing occur in respect to the horizontal part of the gaiter ?

If your going to replace wires in the loom,then I would suggest thin walled cable as;

• The insulation is more wear resistant than the old stuff
• it has more conductors of smaller size and is hence more flexible

I believe that the overall diameters are much the same for a given current rating, but I haven't actually checked this myself.

g8dhe wrote:If you reinforce the wires within the gaiter section then you will generate more problems, as the idea is that they twist within the horizontal section rather than bend. Where about did the break and chaffing occur in respect to the horizontal part of the gaiter ?

If your going to replace wires in the loom,then I would suggest thin walled cable as;

• The insulation is more wear resistant than the old stuff
• it has more conductors of smaller size and is hence more flexible

I believe that the overall diameters are much the same for a given current rating, but I haven't actually checked this myself.

One wire broke and one is chafed at the same place. Hard to tell where this was in relation to anything as it is all sismantled at the moment. The gaiter looks fine and no holes or wear in that

most of our rear end electrics didnt work when we got ours. i did a factsheet in members sec about it.
the cables go for the same reason as the front drivers door.
all i did with ours was completely reloom through the gaiter with all the wires, 5 yrs later its all working aok.

dreamwarrioruk wrote:most of our rear end electrics didnt work when we got ours. i did a factsheet in members sec about it.
the cables go for the same reason as the front drivers door.
all i did with ours was completely reloom through the gaiter with all the wires, 5 yrs later its all working aok.

How do you mean reloom Mike?
You mean just strip back the tape and redo it all neatly and tight?
Or did you replace all the wires?

replaced all the wires from inside the tailgate right through to the inside the pillar on the rear of the bongo interior. if 4 of them had worn through i wouldnt expect the rest to last the test of time.

dreamwarrioruk wrote:replaced all the wires from inside the tailgate right through to the inside the pillar on the rear of the bongo interior. if 4 of them had worn through i wouldnt expect the rest to last the test of time.

I see. Mine arent that bad so i will just do a repair job on it and see if that keeps me going. If anything else fails then i will concider that route. Thanks matey.