85 6.9 ZD28 glow plugs, replacing harness, need parts advice.

[olddesertrat]

Search forum. Lots of good info, need more.
Truck: 1985 Ford F-350 6.9 with ZD28 spade style glow plugs.
Controller bypassed with push button switch on dash.
Looks like original harness has fried somewhere and shorted to ground.
Glow plug spade connectors give solid short to ground even with all glow plugs disconnected and connectors at relay disconnected.
Tested plugs, all appear good at around 1.0 ohm.
Can not find OEM replacement GP harness, seen comments saying no longer available and should just make your own.
There are 7.3 replacement GP harnesses with bullet connectors, but these appear to be too short for older 6.9s.
Understand Bosch 80034 at 11 vdc are better GPs for controller bypass, but for now would like to keep the ZD28s if possible.
The original harness spade connectors are plastic, falling apart and metal corroded.
Plan: Make replacement GP harness like the 7.3 GP replacement harnesses available.
Materials:
1. Small Battery terminal connector will be used as connector at relay. Have
2. Eight 10 gauge wires will come off relay connector, one for each glow plug. 50ft of 10 gauge copper wire on order.
3. Each wire ends with 3/8th female spade connector. Need to order.
Thought spade connectors would be easy to order, has been harder than thought.
Would like advice on where to buy correct female spade connector for ZD28 GPs, with protective covering if possible.
Also any other helpful advice would be welcomed.
Thanks

 

[franklin2]

Do you use ebay? If you want the whole thing covered, you will have to use shrink wrap over the connector after you crimp it, which really works well. You can slide it down to cover the whole connector.

Pardon Our Interruption...

 

[franklin2]

Here's Amazon. You could solder these and then use the shrink wrap.

Amazon.com: NSIXSURIM 20 PCS 9.5mm Brass Tin Crimp Terminal Cable Locking Female Spade Connector 3/8" Thick 0.5mm for 2-2.5mm2 (9.5mm Brass 20pcs) : Industrial & Scientific

Buy NSIXSURIM 20 PCS 9.5mm Brass Tin Crimp Terminal Cable Locking Female Spade Connector 3/8" Thick 0.5mm for 2-2.5mm2 (9.5mm Brass 20pcs): Spade - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

 

[olddesertrat]

Thanks for reply Franklin2
Closest have been able to find so far is Dorman 85447 3/8th female quick disconnect.
$5 for 7 at local Auto Zone. Cheap, correct size and correct fit.
Do agree, for insulation over female part of connector looks like a thick shrink wrap is only option. Was surprise that 10 gauge wire was so expensive on Amazon. Even at local Home Depot #10 wire is currently 94 cents per foot.
Already have 50ft of #10 wire coming in from ebay, but came up with better design that is cheaper and uses less #10 wire.
Instead of using small battery connector at relay, use as much almost entire positive battery cable as needed.
Concept:
1. Buy longest positive 2 or 4 gauge battery cable cheaply available. 6ft available on ebay for $21.
2. Connect one side to relay.
3. Route cable across front of engine in front of injection pump.
4. Turn towards driver seat at driver side glow plugs.
5. Cut cable and terminate little past glow plug #8.
6. Mark locations of glow plugs on battery cable.
7. Cut open battery cable and solder #10 wire and female connector at each glow plug location.
8. For passenger side glow plug bank, cut open battery cable at bank location and solder another length of battery cable going along that bank of glow plugs. Repeat steps 5 to 7.
9. Cover all solder location with Red silicon sealant.
This setup should require only a few feet of #10 wire. Will make this setup when #10 wire comes in, hopefully in a few days.