FULL BOOST Transition Boot Sizer

How to read this. Each side's bundles are packed and enclosed to give a group diameter. The larger group goes to the boot mouth (ØH), the smaller to the tail (ØJ). Each end is rated against the datasheet bores: grips if the group sits between the recovered and expanded bore (slides on, then grips as it recovers), tight if it grips but the expanded bore clears the group by less than 10% of the group Ø (it will go on, but with little clearance), loose if it's below the recovered bore (it slides on, but the boot fully recovers without reaching the group), and won't fit if it's bigger than the expanded bore. There are no manufacturer fit rules for these, so no size is recommended - picking a transition boot is a judgement call about the harness itself. The view just defaults to the smallest 202A that grips both ends, failing that the smallest with no tight end, failing that the smallest that slides on. Pick whichever size suits from the options. 202A parts are non-lipped, intended for harness transitions rather than connector backshells.

Method. Each side is packed as tangent circles and bounded by the smallest enclosing circle, giving a group Ø (same approach as the Full Boost Bundle Sizer). The larger group drives the boot mouth (ØH), the smaller the tail (ØJ). Each end is judged geometrically against the datasheet: grips when the group is between the recovered and expanded bore, tight when the expanded bore clears the group by less than 10% of the group Ø, loose when below the recovered bore, won't fit when above the expanded bore. The 10% tight rule matches the Full Boost Connector Boot Sizer and is set the same way: install difficulty is an absolute-clearance question rather than a shrink-fraction one, and 10% is the industry slide-on minimum, so a percentage of the thing being slid over travels correctly across the size range where a fixed mm figure does not. Tight and loose are cautions rather than fails: both still slide on, they just sit at the edges of the boot's working range, and what to do about either is a decision for the harness. Dimensions are representative catalogue values, so confirm against the parts in hand.

Raychem 202A transition boots. Non-lipped straight transition boots, part numbers 202A111 to 202A196. Expanded (a) and recovered (b) ØH mouth and ØJ tail dimensions are from the TE Connectivity (Raychem) 202A Table of Dimensions. Each part is listed as two explicit options, -25 and -12, each using its own expanded column from the drawing (-25 shares a column with -3/-4; -12 with -100; other dash codes are not listed - confirm against the drawing). The -25 variants are a uniform expanded tube (H and J minimums equal per size); the -12 variants generally expand less, especially at the tail, so slide-on verdicts differ between them. Recovered dimensions and length P are common to all variants. Only the ØH and ØJ diameters are used for fit; the P length is listed for reference.

Bundle ODs. Each bundle OD is entered by the user (typically taken from a wire/cable datasheet or a sub-bundle sized in the Full Boost Bundle Sizer). Packing is a deterministic nearest-fit insertion; the enclosing group diameter is bare, before any sleeving or tape.