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Joined: Jan 2019
Posts: 81
Likes: 2
Ted12 Offline OP
Trainee
Hi All

I accidentally cut off too much length from my Victa 2 stroke powertorque mower high tension spark plug cable and it's now too short to reach up and connect to the spark plug.

I've got some additional spark plug cable but what's the best way to do a nice neat safe joint to add a piece of cable to make it longer so it can reach ?

I was thinking strip both wires back, solder then cover with heat shrink but I wasn't sure what's safe / best.

Any thoughts ?

Thanks
Ed

Joined: Jul 2018
Posts: 2,086
Likes: 80
SENIOR TECHNICIAN
I have personally chopped the head off a self tapper screw, ground to a point and then joined them like that, screwing each together.

then heat shrink.

Joined: Jan 2015
Posts: 1,233
Likes: 32
Junior Technician
Hi Ted12 & Tyler
, I solder together with heat shrink, seems to hold.
speedy


........................Keep your blades sharp......................
Joined: Jan 2015
Posts: 1,487
Likes: 23
AVB Offline
SENIOR TECHNICIAN
Here I replace the complete high lead but it does depends on the coil design. Some older coils it is not possible to do that.

Joined: Apr 2014
Posts: 219
Likes: 10
Apprentice level 3
Almost any form of join will alter the electrical characteristics of the cable, specifically, in this case, increase resistance. This will result in a less powerful spark and, especially as the join in the lead ages, an intermittent spark leading to ignition faults.

These cables are in a very hostile environment with heat, abrasion and fuel contamination being commonplace and expected. Joins are weak points and the insulation around them more easily fails Therefore, it’s best to replace a ht lead in its entirety rather than attempt to join it as heat shrink will eventually fail in the environment. It’s a thermoplastic and is designed to change with heat in a similar range to that experienced in the vicinity of the head.
Once the insulation becomes less effective the spark will jump to other areas causing a fault and, critically, a fire risk with any vapour that may be present.

There are some commercial connections designed to work effectively in these environments but they are uncommon and more expensive than a length of cable.

Joined: Jan 2019
Posts: 81
Likes: 2
Ted12 Offline OP
Trainee
Hi Ironbark

I agree, however I haven't taken the engine off however from what I can see online of videos, the High Tension Spark Plug cable that runs off the ignition coil is all one piece (doesn't plug in) so short of replacing the whole ignition coil module I'd still need to make a join somewhere..

Joined: Jan 2016
Posts: 7,466
Likes: 143
SENIOR TECHNICIAN
Or I can give you another coil, I have heaps of them

Joined: Apr 2014
Posts: 219
Likes: 10
Apprentice level 3
The best bet is to source a spare and Norm has offered so you’re already ahead.

I’ve repaired similar things and to do it well is a significant undertaking and not worth it unless no spare part is available.

Joined: Jan 2015
Posts: 1,487
Likes: 23
AVB Offline
SENIOR TECHNICIAN
IF this is the coil then lead should be replaceable. Usually there just pin or screw at the bottom the tube.
[Linked Image from i.imgur.com]

Joined: Jan 2016
Posts: 7,466
Likes: 143
SENIOR TECHNICIAN
Hi Ironbark,
Only problem here is Ed lives in Hawthorne now that could be half an hour from my place so he could pick up a coil no problems or he could be a 1000 ks away in QLD

Joined: Jan 2015
Posts: 1,487
Likes: 23
AVB Offline
SENIOR TECHNICIAN
Or like me as i am on the other side of the rock.

Joined: Jan 2019
Posts: 81
Likes: 2
Ted12 Offline OP
Trainee
Thanks Normk, I'm going to have a bit of a play with the lead however if I decide to change the whole coil I will get in contact with you, thanks for the generous offer !! Cheers

Joined: Apr 2014
Posts: 219
Likes: 10
Apprentice level 3
Most of mine have mechanisms similar to what avb has shown, and yes, they are very simple to repair.

I am gathering, from the op’s comments, that the lead is on a powertorque and it’s a later type with an integrated module.

To repair this type of unit in a durable manner I’ve gone back to the module; cut and soldered and then sealed in epoxy, waited for it to dry before wrapping with cloth automotive electrical tape and sealing the tape with painted on epoxy.

I wanted to fix the machine for the next day and had very limited access to spares. It did last like that for several years.

Joined: Sep 2022
Posts: 60
Likes: 4
Trainee
For some reason that I forget, or ever knew, my father spliced a piece of V-8 Holden HT lead (wrapped with Leccy tape) along with the Holden spark plug to his Victa Rapier and it ran perfectly like this for at least 15 years.

Only problem was it stuck out too far and kept getting hooked on things if you weren't careful

Danny

Last edited by Dandare; 23/01/23 05:16 PM.

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