WesBell Electronics


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WesBell Electronics, Inc has been a wire harness supplier and manufacturer for over 25 years. We became ISO 9001 Certified in order to improve our customer service and quality of product. We follow specification sheets (data sheets) to make sure the length is within tolerance, the parts are manufactured correctly and the revision level is up to date. Below are some of the recent projects we've completed.


Wire Harnesses


Wire Harness Supplier

Twisted Wire Harness


There are multiple steps to this twisted wire harness including cutting, twisting, crimping, poking, heat shrink tubing and labeling. Each step has tolerances that are checked in our quality department. We may not completely understand why a tolerance is in place, but we know it's important to the customer, so we reject any parts that don't meet the customer specifications.

We keep about 100 completed harnesses on the shelf so that we always have some available for immediate release. We allow the customer to specify how many completed assemblies to keep on the shelf, but it's typically a month's release.


Hook Up Wire Harness

Hook Up Wire Harness


This type of wire harness is a high volume item for WesBell Electronics. We have machines that cut hook up wire to the specified length in excess of 5,000 pieces per hour. We also have foot-pedal crimping machines that press crimp the terminals to each end before inserting them into the plastic housing.

Once the lead wires are cut to length and crimped, each color needs to be inserted into a specific position of the housing called a "pin-out". The customer expects to receive the wire harness with the colors in exact order so that their connection works as planned.


Lead Wire Harness

Lead Wire Harness


In order to manufacture this lead wire harness we cut two black wires and two yellow wires to length. Then we crimp a terminal to both ends which means we need 8 in total. Then we insert the wires into the specified holes of the white house. Finally, we create a label with the customers information and attach it to the center of the harness.


Open Ended Wire Harness

Open Ended Wire Harness


This is an open ended wire harness that we build for a customer. Each of the wires are cut to length and tin dipped on one end. There is a terminal crimped to the opposite end so that the lead wires can be inserted into the plastic house. The final step for this harness is to cut and label a piece of white heat shrink tubing to shrink it over the lead wires.

Wire Harness Data Sheet

Wire Harness Data Sheet


This is a wire harness data sheet supplied by our customer for us to follow. Each measurement is listed with a tolerance (+ or -) that the customer can accept for their application. We always make a first article sample for the customer to inspect and approve before telling us to begin production.

As the customer, you won't have to provide a data sheet for us to build your wire harness or cable assembly. However, upon creating the first article we may also create our own data sheet for you to approve so that our assemblers have a guide as they complete each step of the process.


Lead Wire Assembly

Lead Wire Assembly


This is a new lead wire assembly for WesBell. We recently bid and won the assembly business of a customer that didn't want to build them in-house any more. There are multiple lead wires, connectors, houses and tools that needed to be ordered for this assemly job. It's slightly complicated but the data sheet is very detailed with colors and part numbers referencing exactly what needs to be done.

We've been in conversation with this customer about adding heat shrink tubing to each bundle of wires to separate them. It should make it less confusing for the customer when using the assembly in their application.


Green Wire Assembly With Tie Wraps

Green Wire Assembly With Tie Wraps


This wire assembly, or harness, uses two green wires that are about 22 inches long with four tie wraps placed evenly throughout the total length. Even though it may look like there are terminals crimped on each UL1007 wire before connecting it to the white house, that's not the case. IDC, Insulation Displacement Connectors, slice through the insulation to connect to the copper strands for conductivity. Using IDC connectors will cut out a few steps in the process and lower the labor costs of making the assembly.

Buy UL1007 Wire here >>