Has anyone assembled these ht plugs?

Dave Bilyk

Bronze Supporter
I cant find any info on how to assemble these. Has anyone done these? Getting the lead through the plug is a major challenge but after this and crimping I am not sure whether the brass plug ends up with a 90deg bend in it and exactly how the white plastic sleeve goes in.
These are for the ford gen II coilpacks.


Jac Mac

Active Member
Not sure about the white sleeve, however.. silicone spray 3" on end of lead, slide black boot onto lead until approx 1" of lead out of plug end, bend conductor core back over lead end and crimp brass on lead end. Bend 90° @ necked down area of brass, pull black boot back over brass and finally fit white sleeve over plug end of terminal & into molded receiver for it in black boot... I'm guessing on those last 6/7 words..:)

Dave Bilyk

Bronze Supporter
Thanks jac, I think you are right about the last few words as there is a ridge at one end of the sleeve and looks like a matching cavity in the boot. You reminded me that I do have some silicone spray too. I see that one fitting aid is to tie a wire or piece of string to the lead to draw it through the boot. There is a second smaller crimp area further down the brass connector which could be intended for the core. Plug ends are different and look much easier.
Hi Dave,
I assembled similar boots when I made my HT leads, but was using Ford Gen1 coil packs, so slightly different. I used washing up liquid to pull the cable through, which worked fine, but you do need to use the correct crimping tool, otherwise the cable pulls out during assembly (learnt the hard way..)

Dave Bilyk

Bronze Supporter
Thanks Andy, I managed to do one last night. The most difficult part is getting the lead to turn the corner in the boot which is where a piece of wire helps to pull it through. I will post the technique with some pictures.

Howard Jones

Gold Supporter
We used to use isopropyl alcohol as a lubricant to pull wires through tight spots in the shop I worked at for many years. It is especially useful when assembling pins into rubber pin housings common in electrical connectors and works as good as anything else evaporating to nothing when you're done. I keep a gal around in my home shop. It's works for a lot of things as a lubricant when you don't want to/can't clean up a difficult access spot.

If you use silicon lubes, use food grade because it doesn't have any oils in it.

Here's a video on putting together MSD universal wires sets.

Build your own MSD Spark Plug wires - YouTube
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