Best way to insulate wiring from heat

[rockjeep44]

I've got a handful of ignition wires running close to the framerail about 12in away from my headers. Obviously it gets super hot right around that area and I don't want to melt the wiring. I think the wires would be ok but prolonged exposure could damage their insulation. Whats the best way to protect them from the heat? Thanks
-Andrew

[Hammer]

Put the wires in a loom, then wrap the loom in thermal tape. Usually foudn at places like Summit, etc for fuel line wrapping. Works pretty good. Sticks on one side, reflective aluminum like surface on the other.

[rockjeep44]

Sounds like that would work. Anything other methods to consider?

[Desert Beast]

the only other option is to route the lines somewhere else. you could also get header wrap (same sort of stuff) possibly gain performance? or make an aluminum shield for the wires. but wrapping the wires would be the easiest.

[Nobby]

With 12 inches sounds like you have ample room for a heat shield. Its incredible how much heat is reduced by a thin plate and a 2 inch air gap.

Otherwise lag your headers! :D

[Hammer]

A note on header wrap, this stuff can rust out pipe like no ones business for an off road vehicle. But it does a VERY good job of keeping the heat IN the pipes (do it on race cars with turbos). And it does sound like you have plenty of room for a simple heat shield.

[Wesdog]

I did a loose wrap of Thermo-Tec insulation on my headers and it works well without the problems with a typical header wrap: http://www.thermotec.com/products/full/11240/11240.html

http://www.fullsizejeeps.com/jeeps/files/Misc-Pictures/401_thorley_headers2.jpg http://www.fullsizejeeps.com/jeeps/files/Misc-Pictures/401_thorley_headers1.jpg

[LarryD]

WesDog

Like your exhaust manifold heat shield setup. Is that a custom exhaust?

Are those airpipe connections on the pipes?

Thanks,

LarryD

[Wesdog]

Originally posted by LarryD:
WesDog

Like your exhaust manifold heat shield setup. Is that a custom exhaust?

Are those airpipe connections on the pipes?

Thanks,

LarryDLarry,

The headers are from Thorley and yes those are the air injector ports. The photos were taken before the air injector manifolds were installed.

Wes

[LarryD]

Thanks, Wesdog. I'll check Thorley out. I've got some major work to do on my GW when I get back stateside and am looking for everything and anything that will help the Beast run better. Will probably be doing an engine rebuild and or replacement. Time is critical. The only other set of wheels we have is the wife's Mercedes which stays in Germany (German Spec) when we come home AND the suburban which is getting a bit long in the tooth.

I really like the looks of the GW, always have so I'd like it to eventually be my #1 ride.

Thanks again.

LarryD

[Wesdog]

Larry, headers honestly won't improve performance much if any on an FSJ because of the rpm range normally used. They will heat up the engine compartment and add more noise to the exhaust. The stock exhaust manifolds are actually pretty good. You might switch to a 3" single exhaust with a hiflow CAT if you have a CAT. I think the stock single exhaust is 2.5" but it might be 2.25". That would probably be more bang for the buck and won't heat up things in the engine area. Maybe some others will chime in with more exhaust recommendations.

[Stuka]

Use teflon insultated wires instead of rubber. Teflon wont melt easily, takes about 1200 degrees. This is what we use at work a lot in stuff that runs at high temps. I can set a soldering iron on it for a few mins and it wont get burned. Rubber will instantly.

[FSJeeper]

Originally posted by Stuka:
Use teflon insultated wires instead of rubber. Teflon wont melt easily, takes about 1200 degrees. This is what we use at work a lot in stuff that runs at high temps. I can set a soldering iron on it for a few mins and it wont get burned. Rubber will instantly.I am getting ready to do my wiring, was going mil spec but this teflon stuff sounds good. So where do I find this stuff?

[Stuka]

Should be able to find it at most places that carry wire. it does cost a bit more, but its nice stuff to have if its gona be near heat.

http://www.powerwerx.com/category.asp?CtgID=1060

[FSJeeper]

Stuka, you are the man. Thanks. Stuff is a lot better than mil spec. $80 for 100', should be able to do everything under the hood with that and a lot left over.

[Stuka]

It does have a mil spec number if you look at the specs there. Its good stuff. Some places offer different types of core also. Tungsten, platinum, silver, etc. etc. depending on application.

[J4GRAND]

When I install the Hedman headers in my truck, I plan on getting a piece of "Aeroquip Firesleeve" to insulate the wiring- especially the one that runs on the inside of the right inner fender. This Firesleeve is basically a flexible, rubber-coated fiberglass tube that is used on aircraft engines to insulate wiring, fuel lines and the like. It comes in several different sizes. This stuff might be the ticket for you guys in the warmer climes that are having vapor lock problems.

[Zacko]

I've run wires within inches of headers before and never had problems (at least for several years) If you've got 12" of air (which is a pretty darn good insulator) you don't need to go to any extra expense or effort to keep them cool. And as far as headers go, I'm not sure obout the AMC 360 but for my Ford 360 and Chev 350 they did wonders for low end. I used the Thorley 1 5/8" tubes and turbo mufflers or glass packs on both applications and they both made a noticeable difference on the low end from a single exhaust. My GW does have 2 1/2" head pipes though and that is a step above the 2" from either the Ford or Chev. I didn't really notice any extra heat related problems on either application.
And as for me, I love the sound of new headers too bad they don't stay new very long.

[LarryD]

Lot of good info here for a novice like me. Really appreciate this feed back for my OWN purposes.

Don't know if I like lots of extra heat but as for the comment I made about the Jeep running better, Perhaps I should have said

I'd just like it to RUN.......