Multi-connector harness used for build-to-sample reverse engineering

Build to Sample — Wire Harness Reverse Engineering

Build to sample means Linkssor reverse engineers a physical harness. We measure cut lengths and branch geometry, identify connector housings, terminals and seals, establish wire gauge and insulation, then issue a drawing and an equivalency report for your approval before production. The result is a documented equivalent, not an unverified copy.

Reverse engineering is only useful if it is documented. An undocumented copy leaves you with no drawing, no approved criteria and no way to audit a change — which is exactly the position most buyers are trying to leave when they move a part.

The build-to-sample sequence

Sample receipt and photographic record

The sample is photographed, tagged and logged on arrival. We record condition and note any damage before measurement.

Measurement and identification

Cut lengths, branch coordinates, conduit coverage and terminations are measured. Connectors, terminals and seals are identified by housing marking, pitch and keying.

Drawing reconstruction

We produce a drawing of the harness as measured, in your preferred units and format, for approval.

Equivalency assessment

Where a specified component is unavailable or superseded, we propose an equivalent and state the difference explicitly in the report.

Approval, then controlled build

Production starts only after the drawing is approved. The approved drawing becomes the control document.

Connector and terminal identification set

Branch measurement and identification in progress

What the equivalency report states

Every component identified in the sample, with the identified part number and manufacturer where marked
Any component we could not positively identify, and how we constrained the substitute
Measured cut lengths and branch geometry, with tolerance applied and stated
Wire gauge and conductor construction established by measurement, plus insulation material assessed from markings and behaviour
Differences between the sample and the proposed build, called out individually rather than summarised
Items that require your decision before we can proceed

An honest limitation. Where a connector or insulation material carries no legible marking, identification is inference, not fact — and we will label it as such in the report. If your application is safety-related or homologation-dependent, send the drawing as well, or authorise destructive analysis on a spare sample so the assessment rests on measurements rather than judgement.

How to send a sample

Photograph the harness and each connector before packing
Label the sample with your part number and the quantity you expect to order
State the application and the environment the harness operates in
Declare the country of delivery and whether the end product is safety-related
Send by courier to the Dongguan plant; we will confirm receipt and log it
Tell us if you authorise destructive analysis on a spare sample

FAQ

How many samples should I send?

Two if you can. One is preserved as the reference and one can be sectioned or opened destructively if terminal or seal identification requires it.

Do you return my sample?

Yes, on request. If destructive analysis is authorised, we state in advance which sample will be consumed.

How long does reverse engineering take?

For a typical harness with fewer than ten branches, measurement and drawing production takes 2–4 working days after receipt.

Will the replacement be an exact match?

Physically and electrically equivalent as documented in the report — with any substitution stated. 'Exact' is only claimable when the original component part numbers are known and still available.

Build to Drawing

Build to drawing means Linkssor manufactures strictly to the design record you supply — drawing, BOM and specification. We return a DFM review before.

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