With all rewiring I've done related to Megasquirt and other projects, I am always struggling to find the right size and type of wire. The stuff you buy at the auto parts store or Radio Shack has crappy PVC insulation that melts in the engine bay, isn't gas resitant, or is too thick to allow a lot of wires in a small place. The stuff you buy from home improvement stores is often too large and inflexible. I keep a box of wire scraps left over from the Megasquirt harness, college lab, etc. I got sick of always scrounging for the right wires and running out to the store in the middle of a project. Sometimes I didn't have wires long enough and had to splice different colors together. I finally decided to suck it up and order proper automotive wire in a variety of colors:
It is TXL wire with a cross-linked PE jacket, which is resistant to high temperatures, gas/oil, and has the right jacket thickness like stock wires. Unfortunately, to get this kind of wire at a good price, you have to order in bulk from a company like Waytek Wire. I bought seven colors of 18 gage wire and three colors of 14 gage wire. Each spool is 250 feet. I now have 2,500 feet of wire! That is more than a lifetime supply. This is enough to pass down to my kid's kids. If anyone is interested, I'll probably cut a few lengths and post them in the sale section.
