Motorsport Wiring Harness Diameter Calculator for Mil-W-22759/32 Wires

(Note: If you are using 22759/16 wires choose one AWG size larger to account for the thicker insulation)

Enter Number of Each Size 22759/32 Wire

24 Gauge
22 Gauge Wires

20 Gauge Wires
18 Gauge Wires
16 Gauge Wires
14 Gauge Wires
27500 Shielded 2 Wire 22ga Wires
27500 Shielded 3 Wire 22ga Wires
Harness Diameter: mm

MIL-W-22759/32 wires
are the predominant specification for motorsport harnesses...a bit thinner (15%) than 22759/16 specifications. In laying out your harness documention the number of wires in each branch of the harness can be easily determined. It gets a bit complicated with various splices for analog, digital and chassis gounds as well as 12V and 5V splices. Calculating wire bundle diameters this way saves a lot of guesswork.

27500SB shielded cable is typically used for cam and crank signals.

Twisted pairs are just two wires for VR sensors and three wires for Hall Sensors. EGT probes and Knock Sensors acan use two wire shielded with solder splices for the shieldling back at the ECM.

In choosing Raychem shrink products like DR-25, ATUM, and SCL tubing as well as Raychem molded products like boots, it is helpful to have an idea of the harness wire bundle diameters. It gets expensive ordering the wrong parts. 222K152-25-0 left above.  202K153-25-0 right above. ProwireUSA has the full line of Boots and dimensions and suggested Raychem Molded Boot for specific connectors.