I did my time assembling harnesses at a robotics firm years ago. I made all sorts of harnesses and cables. The materials are not very expensive. The work is tedious but not technically difficult hence why I made assembler's wages. The tools are anywhere from 50 to 300 bucks a pop but you only buy them once and you only need a few. After you are tooled up, you can make lots of harnesses, not just these. If you figure you need say 4 hours to make one, that's a lot of time for someone who has become familiar with the process, you can go from there figuring your costs, how long it will take to recoup investment..etc... You'd want to make some sort of lighted test fixture where you just plug it in and if something doesn't light up, it's bad. That way it is easy to make them en masse and control quality.


Another benefit is that your product will be new, not a spliced together of old.


Frank.