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Old 05-15-2009, 12:42 AM   #1
sxynerd
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1996 Ford Mustang
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Join Date: Feb 2006
Vehicle: Stock 96 GT
Location: Bay City, Michigan
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Default Home made o2 extensions

36$ is what o2 extensions cost if you have Long tube headers. Depending on what you have in your garage this could save you about 30 bucks. I just needed to replenish my solder when I was done.

This is what you need.

8 equal lengths of wire. It could be different colors or all the same like what I used here.

Soldering iron/gun
Solder
Heat shrink tubing
Black tape
Wire cutters/strippers
Convoluted Tubing (CT) 1/4 or 3/8's
Heat Gun or lighter
Wire pick



I will be extending the cars harness but it can as easily be done to the o2 sensor itself for easy access. The benefit of extending the harness is the harness isn't going to go bad and need replacing.

  • First step would be to clean and clear away the tubing from the o2 wiring harness. Pull the main wiring away from the harness so you can access more of them for relooming later.



  • I will be cutting one wire at a time and extendeding each wire individually.
  • Next prepare each wire. Use your favorite technique for twisting and prepping the wire for solder.




  • Next use your Soldering Iron and heat your wire and solder your connections. There are lots of different ways to do this but this is the noob way to make it was easy.

  • Heat the wire and touch the tip of the Iron to the wire, then going slow, brush your wire against the tip allowing it to melt into the wire.


  • Now that you have the wire solder on one side, cut your heat shrink. 2 pieces per wire. This is how I did it so I didn't forget the second heat shrink. I tied a knot on the end of one wire with the 2 pieces already on it. (Everyone does it)


  • Next use your heat gun or lighter to shrink the tubing around the wiring.


  • Here is the one side competed. I also included one done without heat shrink if someone wants to use black tape instead. (I did redo it, lol.)


  • Next use your 1/4 or 3/8 CT.
  • Starting from the base nearest the harness use your back tape to wrap around the wires, then onto the CT making sure to overlap with every motion around the harness.
  • Here is the finished product.

Last edited by sxynerd; 05-15-2009 at 01:34 PM.
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