How to: restoring your old Unobtainium Champion spark plug cables
Posted: Mon Oct 14, 2024 7:44 pm
I thought I'd share this restoration guide for the old "Champion" spark plug plugs with you, because recently someone asked me on Facebook to explain how I did it.
Initial situation: I had a set of original ignition cables from my Innocenti Cooper that I actually wanted to keep. Unfortunately, not a single one had conductivity and the plug boots hard as hell. .
To prepare, I bought a set with special crimping pliers and associated terminal contacts (those for the spark plugs and those for the distributor cap) from Amazon. The set cost a hot 38€. (https://www.amazon.de/dp/B082MFZRFH?ref ... asin_title)
On ebay I found an almost matching 7mm green copper braid spark plug cable for next to nothing.
The crimping tool produced consistent results. Once you get to grips how it works it is like shelling peas.
On the dizzy end I fitted the standard 90deg-crimps as I could not fit the old-style side entry cap to the electronic dizzy.
To finish it of I had my son (who is a keen model builder) paint the embossed "Champion"-writing in white acrylic-paint.
PS: I also looked at the Green Spark Plug Ttd. - but the crimping tool there cost a flippin 150 quid and their green cable has been sold-out for ages. They have the genuine spark plug terminal, but this is - whilst original - inferior to the one I used.
The whole shebang:
The old cables - not very pretty nor in working order
All hunky dory again, awaiting paint for the embossed writing
The crimping set:
Initial situation: I had a set of original ignition cables from my Innocenti Cooper that I actually wanted to keep. Unfortunately, not a single one had conductivity and the plug boots hard as hell. .
To prepare, I bought a set with special crimping pliers and associated terminal contacts (those for the spark plugs and those for the distributor cap) from Amazon. The set cost a hot 38€. (https://www.amazon.de/dp/B082MFZRFH?ref ... asin_title)
On ebay I found an almost matching 7mm green copper braid spark plug cable for next to nothing.
- In order to be able to remove the age-related hardened spark plug caps from the cable, put them in boiling water with lots of added fabric softener for a few minutes.
- Immediately afterwards - hold the rubber and pull the cable with terminal out to the rear. It takes a bit of a jolt, but usually it works without causing any damage.
- Then crimp the terminals from the set to the new cut to length ignition cables. Plunge the spark plug connector into boiling water with washing-up liquid again.
- Now press and push the cable with terminal end into the still soft spark plug connector boot with a little force, but without kinking the cable!
Once everythingh is together, clean and test for conductivity!
The crimping tool produced consistent results. Once you get to grips how it works it is like shelling peas.
On the dizzy end I fitted the standard 90deg-crimps as I could not fit the old-style side entry cap to the electronic dizzy.
To finish it of I had my son (who is a keen model builder) paint the embossed "Champion"-writing in white acrylic-paint.
PS: I also looked at the Green Spark Plug Ttd. - but the crimping tool there cost a flippin 150 quid and their green cable has been sold-out for ages. They have the genuine spark plug terminal, but this is - whilst original - inferior to the one I used.
The whole shebang:
The old cables - not very pretty nor in working order
All hunky dory again, awaiting paint for the embossed writing
The crimping set:
