FULL BOOST Connector Boot Sizer

How to read this. Part numbers come straight from the boot selection charts and are keyed to shell size; the Hellermann range is filtered to the boots recommended on the FC Lane 8STA motorsport selection sheet, and every size 01-24 now carries full dimensions and fit checks. The tool cross-checks the boot's recovered bore against the connector knurl diameter, and lists the other boots, across both makes and all sizes, that would also fit over the same connector. That headroom is useful when you have a lot of splices or a packed back-end to fit inside the boot. A custom OD, when entered, replaces the knurl diameter in every check; with no shell size selected, the tool derives the closest-fitting size from the OD.

Lengths. The P length drawn in the schematic uses the catalogue datum, which differs by boot type: straight boots are overall length end to end; 90-degree boots run from the mounting-leg centreline to the tail tip; the 90-degree D-series runs from the top of the boot to the tail tip. Lengths are therefore not comparable across types. 1038-4 and 1183-4 have no published length (supplier listing only) and show no P dimension.

Method. These boots are lipped - a moulded internal lip hooks behind the connector knurl, so full recovery is the intended fit, not a loose one. Fit is judged in two parts. Slide-on: the expanded mouth ØH must clear the knurl ØA by at least 10% of the knurl diameter, the accepted minimum clearance for sliding heat-shrink over an obstruction; anything under that reads as tight. (The selection charts' own tightest regular pairing clears its knurl by 11%.) Grip: the knurl must stop the boot inside its shrink range, between the recovered bore and the expanded mouth, so the lip seats; a boot that would recover fully past the knurl reads as loose, except for the manufacturer-recommended size, which is trusted to seat. The tail is judged on geometry alone - it flags only when the bundle won't pass through the expanded tail, or sits below the recovered tail bore. Knurl ØA, boot ØH mouth and recovered bore, and the ØJ tail are all real catalogue dimensions; representative values, so confirm against the parts in hand.

Connector knurl (ØA). Shell-size A dimension over the knurl, from the Eaton / Souriau 8STA & 8TA motorsport connector catalogue (2025), cross-checked against the intermatable Deutsch AS series in the TE Connectivity AS interconnection data sheet (1-1773721-8).

Raychem boots (202K / 222K). Expanded and recovered ØH / ØJ dimensions from the TE Connectivity (Raychem) molded parts data sheet (1-1773853-4).

Hellermann boots. Boot part numbers and dimensions from the HellermannTyton heat-shrink boots for 8STA and the HellermannTyton moulded shapes for 8STA motorsport selection guides. The exceptions are 1038-4 and 1183-4: no manufacturer datasheet could be traced for either part, so their dimensions are taken from a supplier listing rather than manufacturer data - verify against the parts in hand before relying on them.