id try some sort of header wrap first , it would be the cheapest. i can remember when my dad had a built elcamino, put headers on it melted wires in 15 min. wrapped the headers never had a problem again. worth a shot...

 

Yeah I'm planning on wrapping them before anything else because it's the cheapest option and doesn't require me removing them (even though it's a PITA).

Does anybody know if it's possible to put a 90 degree boot on the spark plug end of the wire so I could route the wire under and around the headers instead of through them? And if so, how I would go about doing that? I would just need to do this on the #4 cylinder. There is just so little room to work with that with the straight plug it ends up right up on the headers.

 

Hey man, I don't know if you're still having this issue. I've run some cheap shorties on my JK for the past few years and the steps you've taken should be able to handle the heat IF you are careful how you route the wires. The passenger side needs to be routed up like the long tubes pictured in this thread are routed. On the drivers side, it's really important to route the wires on the front two cylinders downward. I put 90 degree boots on the front two boots and loop them down and then towards the front and back up well in front of the header and to the coil on top.

On the drivers side I used longer sections of DEI Ultra Sheath MA on the long loops and the DEI plug boots on all of them. The issues burning the wires stopped but the amount of heat from the shorties does affect many other things too, like the battery box getting brittle from the heat over time.

I'm in the midst of putting on long tubes now, sorry I don't have pictures of how the wires are routed.


RT