How To Protect Spark Plug Wires From Headers And Melting?


If you’re like most car enthusiasts, you love headers. The louder and harsher they sound, the better! But if you’re not careful, those headers can be very dangerous to your car’s electrical system. 

So, header modifications are one of the best and most popular ways to improve the power and sound of your car. 

This post will show you how to protect your spark plug wires from header and melting. Read on to learn more!

Melting Problem Of Spark Plug Wires  

The spaces within an automobile engine are relatively small. When wires within an engine grow hot, they can melt and create sparks. A spark plug is typically installed next to an engine’s header. These cables contain silicon jackets with several insulators. 

However, it cannot withstand the heat generated by the headers. As a result, the wires may be readily burned down. These plug wires, as we all know, are critical.

If the wires are broken in any way, they will stop conducting electricity and prevent ignition, since broken wires can’t provide appropriate electric sparks to a combustion chamber.

So, the engine will not burn the gasoline due to a lack of available sources. Again, if there is insufficient gasoline usage, the engine will not function effectively. As a result, performance will deteriorate.

How Do You Protect Spark Plug Wires From Headers And Melting?

It is critical to understand how to avoid melting spark plug wires. When attempting to resolve the problem, you might use a variety of measures, such as wrapping the wires and installing heat shields. 

Now we will go through each strategy individually. Let’s get started! 

Tape the wires 

A simple piece of scotch tape cannot prevent wires from melting. Likewise, even the application of electrical tape will not stop ignition voltage. So what can you do right now? 

Luckily, there’s a simple solution to keep you away from the headers if your car has plastic caps or some spacer. 

However, they can’t go against overheating and firing up wires due to voltage differences in proximity with earth-ground potentials.

Heat shields 

Heat shields can separate the hot wires from inside and outside. So if you’re searching for an easy solution to keep your plugs safe, this might be just what you need! They are often used for spark plug wire insulation.

This type is suitable for keeping sparks in one place so they can’t go anywhere else. It also lets air through and protects against any trying to get in.

Insul boots

These insulating boots are made of materials that can withstand high temperatures. In addition, they help reflect and block heat. 

Ring-shaped boots fit between cylinder heads. This thermal material is so powerful that it can endure temperatures as high as 1200 °F  and interrupt an extra 2000 °F!

Heat protector boots 

HP boots are ceramic and stainless steel insulating elements. They are intended to offer a thermal barrier even in harsh temperatures. The boots come in various configurations, including 90 degrees, 135 degrees, and pre-formed straight flexible.

The spark plugs would not be placed near these boot guards. Therefore, there would be no need for a ring to hold them in the sequence. In addition, these boots can have temperatures ranging from 1800 to 2200 °F!

Lava boot shield 

Lava boots are san insulation shields containing hot materials, like basalt. This lava-filled footwear offers excellent protection against cold temperatures and can provide year-round use!  As a result, another benefit of this shield is its adaptability.

You might install them in the manner specified by the parameters. However, they will require inventive rings. The lava boots can withstand temperatures as high as 1200 °F!

Other Ways

You can also use different things to keep your wires from melting. Again, the materials are separate or combined. We will discuss them in detail with an example of their work!

Insulation sleeves 

These sleeves hide the cables. They’re made from a variety of heat-insulating materials to help keep your car’s engine cool and running smoothly! 

However, there is one disadvantage: if you don’t take care, it could damage the insulation over time, making for an unsafe driving experience.

Zip ties 

It is the best way to prevent a fire hazard and keep your wires safe. 

In addition, they will make sure that nothing contacts hot surfaces, which could cause damage or wear-and-tear on both parts of this installation process! After they’re done, you need to check around these cables in order.

Zip ties are typically seen in many vehicles, since the majority of manufacturers want to handle the issue seriously. However, you may also inspect the wiring on your own. Examine the motive by opening under the hood and checking whether the wiring is secure.

Regular maintenance 

Regular maintenance is the most effective solution to any problem. Therefore, you should get the engine inspected at a repair shop regularly. During routine service, the shop will identify any emerging problems. 

You’ll be able to find the issue quickly, and with a bit of common sense, it will not take long. Melted wires are an easy indicator. So you can fix whatever is causing such problems!

Avoid the edges

When wires are near sharp objects or header edges, they are readily damaged. Any broken component will absorb heat from its surroundings.

If you notice any broken or frayed wires, don’t hesitate to replace them right away. Electrical tape will help protect your cables from further damage as well!

Fiberglass socks

Fiberglass insulation is widely used nowadays. It primarily employs high-quality silicones. In addition, fiberglass socks provide excellent heat insulation.

You can tie back the socks, and the wires will no longer be in the range of the headers. As a result, it can withstand extremely high temperatures.

Final Thoughts

It is more important than ever to protect spark plug wires. That’s why we’re here!

Hopefully, our article “How to protect your spark plug wires from header and melting?” can assist you in learning about several solutions for safeguarding your car. 

Besides, if you are looking for help with your car maintenance, don’t hesitate to contact us.

Leave a Comment