Every connection going to the ECM and MCM will pass through my plug in boards. This requires that my connections are up to factory quality, which is why I must have the crimps applied to the pins with the correct factory applicators. Over crimping can cause stress cracks on the pin body, and possible failure, under crimping will cause wire pullout or intermittent connections.The small pins also require a special tall but narrow crimp in order to fit properly into the connector. No room for compromise here.
Good news. After contacting the AMP/TYCO field application engineer Rick Grawehr, things started to improve.
He dug right in, and checked his database as to harness job shops that had the correct tooling, and found RAM electronics in NJ, who has the proper factory automatic tools, and can crimp the terminals onto the 2" wire I require. They can turn it around in only a week, so the wire crimp issue is solved. The cost is pretty high when we consider that I need nearly 20K crimps, but it is in the ballpark that I have been getting for quotes, and tolerable. The pins are on the way to Ram electronics as of (8/19/08). Another piece of the puzzle has been solved.