If a splice in a bundle is not staggered properly, what is a likely consequence?

• A. Temperature rise at the splice
• B. Insulation thickness increases
• C. Weight distribution changes
• D. Bundle size increases

Answer: (D)

When splices are staggered, the extra thickness from each splice is spread along the length of the bundle, keeping the overall diameter roughly constant. If splices aren’t staggered, several splices sit at the same location, causing their added insulation and connector bulk to pile up there. That creates a larger bundle size at that point, which can lead to routing clearance problems, chafing, and difficulty fitting the harness within its designed path. The other effects listed aren’t inherently caused by a lack of staggering: temperature rise at a splice depends more on current and contact resistance, insulation thickness isn’t increased by staggering, and weight distribution changes are not a primary consequence of splice alignment.