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Wiring Zen - Electrical

How To Reach Wiring Perfection-Painlessly

By Sean P. Holman, Photography by Sean P. Holman
  • From the barrels, the wire is measured and placed on more manageable spools.
  • From the spools, the wires are run through a machine that labels each wire, and adds a stripe, if needed.
    From the spools, the wires are run through a machine that labels each wire, and adds a str
  • Next, the wire goes through another machine that cuts the wire to a predetermined length and strips the ends.
    Next, the wire goes through another machine that cuts the wire to a predetermined length a
  • Once the wires are labeled, cut, and stripped, they are hung on these trees until they are needed for assembly. The wire trees are one of the most important tools at Painless, because they neatly store wires and harnesses at different stages of production.
    Once the wires are labeled, cut, and stripped, they are hung on these trees until they are
  • Small parts, such as headlight switches and flashers, are preassembled before joining the main harnesses.
    Small parts, such as headlight switches and flashers, are preassembled before joining the
  • The wires are then removed from the trees and placed together on hangers prior to being joined at the main harness.
    The wires are then removed from the trees and placed together on hangers prior to being jo
  • All Painless wiring harnesses are skillfully assembled by hand, utilizing layout boards, in batches of 200 to 300 at a time, over the course of 30 to 45 days.
    All Painless wiring harnesses are skillfully assembled by hand, utilizing layout boards, i
  • Before they are packaged, each harness goes through a thorough quality check on a test board designed to check that every connection is working properly.
    Before they are packaged, each harness goes through a thorough quality check on a test boa
  • When completed, harnesses are hung, ready for packaging.
  • Each completed package is inventoried in the warehouse until it is time to be shipped out to an awaiting customer.
    Each completed package is inventoried in the warehouse until it is time to be shipped out
SOURCES
Painless Performance Products
8-17/-244-6212
painlessperformance.com
By Sean P. Holman
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