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Spark plug wires are the crucial factor in the combustion chamber of any engine. The wires produce sparks that help with the ignition. On the other hand, headers are necessary accessories that help push the exhaust gases from the cylinder. It can improve the engine’s performance. While the exhaust stroke headers become very hot. Such heat can easily melt down any plastic or polymeric materials. The problem also stands for spark plug wire.
The question is how to protect spark plug wires from headers and melting? In this article, we will discuss the methods of plug wire protection and save them from melting.
Spark Plug Wires with Melting Problems
A car engine has very compact spaces. Typically, spark wires are situated beside headers. When the headers get heated, there is always a chance to melt down the wires. Mainly, these wires are made of silicon jackets and many insulators.
But it cannot handle the heat produced from the headers. Therefore, the wires can be melted down easily. As we know, these plug wires are essential.
If the wires are damaged somehow, the ignition process will be interrupted. That is because damaged wires cannot pass proper electric sparks to the combustion chamber.
The engine will not get enough sources to burn the fuel. Again, without enough fuel consumption, the engine cannot run properly. Hence, the performance will fall downwards.
How to Protect Spark Plug Wires From Headers And Melting?
It is crucial to know how to protect spark plug wires from melting. You can follow numerous approaches when trying to solve the issue, including taping the wires and deploying heat shields. In this article, we are going to discuss all of the methods one by one. Let’s go!
#1. Tape the Wires
A simple scotch tape will not do anything to stop the melting of wires. Even if you use electrical tape, it cannot prevent the ignition voltage. Is there not anything that you can do immediately? Fortunately, you can.
The tape can be used with plastic caps or with some spacer so that it can be placed underneath the wire. If you use them with the tapes, they will ensure enough distance from the headers. Another advantage will be that the wires will not arc to the ground.
Other than the spacing, the electrical tapes cannot give any protection from heat.
#2. Heat Shields
Some heat shields can isolate the outer and inner heat in a spark plug wire. If you are looking for a solution to melted wires, these heat shields are the answer for you. They are very popular when it comes to insulating the plug wires. Let us show you some of the examples of heat shields so that you can acknowledge their importance.
Mainly, these insulation boots are made of conventional thermal- barrier materials. They help to reflect the heat. The ring-shaped boots go between the cylinder heads. These thermal materials are so strong that they can withstand 1200-degree Fahrenheit temperature. They can also intermit extra 2000-degrees.
#4. HP Boots
Heat protector boots are made of stainless steel and ceramic insulation materials. They are designed to provide a heat barrier even in extreme conditions. The boots are of different shapes like pre-formed straight, 90-degree, and 135-degree, all the while being flexible.
These boot protectors would not side up the spark plugs. Therefore, you would not need any ring to keep them in a pattern. The HP boots can handle 1800-degree Fahrenheit and can intermit 2200-degree.
#5. Lava Boot Shield
They are pretty similar to Insul-Boots but with different buildup materials. These lava boots are made of unique high-temperature basalt materials. That is why flexibility is another advantage of these shields.
You can install them according to the configurations. But they will need innovative rings just like the Insul boots. The lava boots can handle 1200-degree Fahrenheit, and they can also intermit 2000-degree Fahrenheit.
Other Methods You Can Use
There are some other products you can use to protect the wires from melting. The materials can be used individually or all together. Let us discuss them and show you their functions.
#1. Insulation Sleeves
These sleeves are used to cover the wires. Several heat-insulating materials are used to build them. Using such materials help to sustain the extreme heat of your car’s engine. But there is a problem with the insulation sleeves.
You cannot use them directly to cover the wires. Any cover that is placed before will be needed while installing the sleeves. The result will be that it will give you an extra layer of heat insulation.
#2. Zip Ties
We can that it is the easiest way to separate the wires. They will ensure the wires should not touch any hot surfaces. After the installation, you should check whether the wires are secured or not. They will also help to prevent the wires from getting cut or being worn down.
You will notice the zip ties in many cars. That is because most of the manufacturers have taken the problem seriously. You can also check the wires by yourself.
Take a look at the engine by opening the hood and see if the wires are secured or not. When you find some problems or are confused, you can use some zip ties to tie them. The most significant advantage is the availability of zip ties. They are also very cheap compared to other methods.
#3. Regular Maintenance
The best solution to any problem is regular maintenance. You should go to the repair center to do a routine check of the engine. The inspection will be for all the parts under the hood. Any developing problem will be noticed during the maintenance.
If you can find the problem, it will be easy to fix them. For example, melted wires can be detected easily if you check the engine. Then the particular solutions will be applicable.
#4. Avoid the Edges
There is a possibility when the wires are situated near the header edges or any sharp edges. It is because edges can easily be damaged. Any damaged part is very to absorb heat from the surroundings.
Suppose you see some damaged or frayed part of any covered wires. Immediate replacement of those wires is needed. Or else you can cover the damaged part with electrical tape. This will help to prevent further damage or a chance of melting the wires.
#5. Fiberglass Socks
Using fiberglass for insulation is very common nowadays. Mainly, they use suitable quality silicones. When you put on some fiberglass socks, it will repel the heat very successfully way.
The socks can also be tied back. Then, the headers will not be in range to touch the wires. Silicon socks can handle the heat in very extreme conditions.
The Right Wire Protection!
That is an excellent question. How should you know which method you should use? The answer is pretty straight cut. You have to look under the hood and check the engine first. Then, the problem will be determined.
Suppose you see the wires are getting near to the headers but do not meltdown yet. Some zip ties can easily solve the problem. If you think of further future, you can install some heat shields. They will continue to save the wires in the long run.
Again suppose, you see some smokes are coming from under the hood. Would you use a quick method to solve the problem? It will be recommended to avoid temporary solutions. You will need to replace the spark plug wires immediately.
Another way to choose the proper protection is to ask the manufacturing company. They know their machines best, right? If you ask them about the problem, they can guarantee you. Or else they will give you some extra protection layers for the plug wires.
You must know that the wires are the most crucial parts of the electrical system of your car. The engine of any car produces a lot of heat.
Therefore, the wires are always at risk of melting down at any moment. You have to choose better quality spark plug wires. It will help to avoid constant troubles about heating issues. When you see some wires have been melted, there is nothing you can do but replace them.
You have to maintain regular maintenance to identify any problem. A routine checkup of the engine is also possible when you know about the parts very well. Heat shields and insulation sleeves are a very good option in answering how to protect the spark plug wires from headers.
Even if it costs you some extra money, do not hesitate to have an additional protection layer. Without solving the problem from the root, you might face severe issues for the engine.
The discussion has come to an end. Let say you have understood the topic of how to protect spark plug wires from melting. We have tried to explain the methods and ways of protection very clearly. Therefore, you should be careful about such issues. Wish you a piece of good luck.