Rick - You can do this fairly easily. I don't have the lengths for the wires on your motor, just 0-540s. Another easy solution is call
If you can get the length of the wires, it is a fairly easy job. After you get the lengths of the wires and what length goes to what cylinder, the easy part starts.
Order a Magneto grommet for the style mag you have. Take it to the Hi-Lo and figure out what size spark plug wire fits the grommet best. Get a tube of di-electric grease, the color & style spark plug boot you like, and the metal spark plug grommet to fit that style, and find out if they will sell spark plug wire off the roll or just by the roll.
If by lengths, either buy just enough wire for one set, plus two extra wires the length of the longest wire (for spares) or buy enough for two complete sets. I make sure that each wire is 1/2 inch longer than what is required.
The next set is buy a small packet of pop-rivets. I use 1/16 inch diameter pop-rivets. Push the shaft out the rivet the reverse way and save the metal cap. You will need 8 caps.
I start by stripping 1/4 inch on both ends of the wires. Run the wire through magneto cover plate and to the back side of the grommet. (The nipple part of the grommet faces into the magneto). Put the wire through the nipple, snug it up against the inside of the nipple, and slide a rivet cap over the exposed wire with the wide cap against the nipple, then crimp the cap to the wire.
The opposite end needs to be stripped back 1/4 inch of wire and the plug grommet crimped on. The bare wire lays back against the rubber and gives good contact to the metal grommet. The push the plug boot on and one wire is ready to go.
Your magneto plate should have the cylinder numbers by each hole for the wire that will run through that hole. Make sure the right length goes in each hole.
I coat each part very liberally with Di-Electric grease and have not had problems with any loss of charge, shorting, spark jumping. But there is a small dab in the inside of each nipple, on each bared wire end, under the spark plug grommet, and under the plug boot (helps that go on nicely).
Typically you can save the magneto grommet if it is not to old. Then replace it. If the holes in the magneto plate are larger than the plug wire, these HAVE TO BE PLUGGED with 100% silicone or you will get humidity problems and every thing will go bad quickly. In fact, I fill them even if the hole is a tight fit just to prevent any moisture leakage.
