Mil-Spec Bulkhead Connector

[Turbo67camaro]

I decided to spend some extra dough and go the mil spec circular connector route. While more expensive, the price differential is not too extreme. Prices vary a LOT from one seller to another, so SHOP AROUND! Here is what I just ordered from http://connecticc.com. They have excellent prices, but their website is a bit slow. I think their inventory server with quantities on hand was just offline, as everything was showing out of stock, whereas a couple of days ago everything was in stock with fairly large quantities on hand. Another good seller with competitive prices is http://prowireusa.com.



# of connection count by size summary
==============================
Firewall (connectors 24-61, 24-31, 24-19):
a) 61 size #20, 31 size #16, 19 size #12

4L80E Transmission tunnel (connectors 22-41):
b) 27 size #20, 14 size #16

Trunk (connectors 16-14):
c) 8 size #20, 6 size #12

Connector size to wire gauge to max amps cross reference:
1) Size 12 = AWG 14-12 = max 23.0 amps
2) Size 16 = AWG 20-16 = max 13.0 amps
3) Size 20 = AWG 24-20 = max 7.5 amps

Total # Connectors summary:
a) 96 #20
b) 45 #16
c) 25 #12
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166 total connections

Overkill? Perhaps, but I only want to add these connectors once.
Able to handle future added electronics? Very likely.

I bought a used DMC AF8 M22520/1-01 crimper with a TH1A M22520/1-02 turret attached for $129.99 off ebay.

I went with flange receptacles to avoid having to cut D shaped holes recommended for the jam nut receptables (i.e. rotation prevention). Narrow flanges instead of wide flanges to conserve space.



I'm considering using 90 degree strain relief adapters. They run about $10 to $15 per connector side on http://mouser.com. Again, the prices on the strain relief adapters varies dramatically, so shop around.

My electrical system is ISIS Power based, which results in a LOT less power wires being routed through panels, so the appropriate connector sizing and counts will likely vary a lot for a car that is traditional wiring. A traditionally wired car will likely need more larger gauge connections.