Raychem DR-25 Heat Shrink

Raychem DR-25 is an irradiated cross-linked polyolefin heat shrink tubing manufactured by TE Connectivity to MIL-DTL-23053/16. It is the standard jacketing material for motorsport wiring harnesses: flame-retardant, chemically resistant, and flexible across a −75°C to +150°C operating range. Radiation cross-linking gives DR-25 elastic memory — the tubing returns to its original expanded diameter if reheated above the recovery temperature, which allows it to be repositioned during assembly before final heat application.

Stocked in seven sizes from 1/8″ (3.2 mm) to 1″ (25.4 mm), sold per metre or on full factory spools. A thin-wall variant (DR-25-TW) offering approximately 30% weight reduction per metre is available on request for weight-critical builds.

Specifications

Property Value
Shrink ratio 2:1
Temperature range −75°C to +150°C
Recovery temperature 175°C minimum
Longitudinal shrinkage 10% maximum
Tensile strength 8 MPa minimum (per RK 6008/1)
Elongation at break 200% minimum
Dielectric strength 8 MV/m minimum (IEC 243)
Voltage withstand 2,500 V rms (post-environmental)
Flame retardant Yes
Chemical resistance Aviation fuel, diesel, hydraulic fluid, lubricating oils
Adhesive liner No
Colour Black
RoHS Compliant
Primary standard MIL-DTL-23053/16 Class 1
Additional standards AMS-DTL-23053/16, VG 95343 Part 5 Type D, VDE 0341/Pt 9005, Def Stan 59-97 Issue 3 Type 6B, BS 4G-198 Part 3 10A
Internal specification TE Connectivity RK 6008/1

Size Reference Table

Wall thickness values per TE Connectivity RK 6008/1. Values for 3/16″ and 1″ are not listed in publicly available specification sheets — refer to the TE Connectivity datasheet for those sizes.

Size Supplied ID Recovered ID Wall thickness (recovered) Full spool
1/8″ (3.2 mm) 3.2 mm 1.6 mm 0.76 mm 100 m
3/16″ (4.8 mm) 4.8 mm 2.4 mm — 100 m
1/4″ (6.4 mm) 6.4 mm 3.2 mm 0.89 mm 100 m
3/8″ (9.5 mm) 9.5 mm 4.8 mm 1.02 mm 100 m
1/2″ (12.7 mm) 12.7 mm 6.4 mm 1.22 mm 60 m
3/4″ (19.0 mm) 19.0 mm 9.5 mm 1.45 mm 60 m
1″ (25.4 mm) 25.4 mm 12.7 mm — 30 m

Select a size where the supplied (expanded) inner diameter is at least 1.1–1.2× the outside diameter of the bundle or component. After recovery the tubing must grip firmly — the recovered diameter should be equal to or slightly smaller than the bundle OD.

Size Selection Guide

Typical application Recommended size
Individual wire joints and terminations (22–26 AWG) 1/8″ (3.2 mm)
2–4 wire branches, thick-wire splices (12–16 AWG) 3/16″ (4.8 mm)
4–8 wire sub-branches, connector backshell exits 1/4″ (6.4 mm)
8–15 wire harness branches and sensor trunk runs 3/8″ (9.5 mm)
15–25 wire harness trunks, ECU harness main runs 1/2″ (12.7 mm)
25–50 wire main loom sections, engine bay runs 3/4″ (19.0 mm)
50+ wire chassis trunks and full loom jacketing 1″ (25.4 mm)

Wire Compatibility

DR-25 is designed for use with mil-spec wire only: M22759/32 (Spec 55, ETFE/Tefzel, rated to 200°C), M22759/16, or equivalent aerospace-rated wire with PTFE or ETFE insulation.

Do not use DR-25 over standard PVC-insulated wire. DR-25 requires a minimum surface temperature of 175°C for full recovery. Standard PVC insulation begins to soften and deform above approximately 105°C. Applying DR-25 over PVC wire will damage the insulation before the tubing has fully recovered.

Installation Notes

Recovery temperature: A minimum surface temperature of 175°C is required at the tubing, not at the heat gun outlet. Gun outlet temperatures are significantly higher — use a reflector or concentrator nozzle to wrap heat evenly around the tubing and avoid scorching.

Nozzle selection: For sizes 1/2″ and larger, use a wide-aperture reflector nozzle rather than a straight nozzle. This distributes heat around the circumference and avoids uneven recovery.

Longitudinal shrinkage: DR-25 can shrink up to 10% in length during recovery. A 500 mm sleeve will shorten by up to 50 mm. Pre-cut lengths longer than the finished dimension and route the harness fully before applying heat.

DR-25 vs SCL

DR-25 and SCL are both Raychem cross-linked polyolefin tubing, but serve different roles:

DR-25 SCL
Shrink ratio 2:1 3:1
Primary use Outer loom jacketing Splice protection, tight transitions
Standard MIL-DTL-23053/16 MIL-DTL-23053/5

Use DR-25 for jacketing harness runs and branches. Use SCL where the higher 3:1 ratio is needed — for example, splice protection over 22 AWG wire (0.86–1.14 mm OD) where DR-25 1/8″ would not close sufficiently.

DR-25 vs DR-25-TW

DR-25-TW is the thin-wall variant of DR-25. Both meet MIL-DTL-23053/16 and share the same chemical resistance and operating temperature range.

DR-25 DR-25-TW
Shrink ratio 2:1 2:1
Wall thickness Standard ~30% thinner
Mass per metre Standard ~30% lower
Abrasion resistance Higher Lower
Primary use Standard motorsport harness jacketing F1, endurance, aerospace — weight-critical builds
Standard MIL-DTL-23053/16 MIL-DTL-23053/16
XTRA stock In stock Available on request

Choose standard DR-25 for most motorsport harness builds. Specify DR-25-TW only when the weight saving justifies the reduced abrasion resistance — typically in professional endurance or single-seater applications with a defined weight budget.

DR-25 Alternatives: Deray V25

Deray V25 (DSG/HellermannTyton) is a functional MIL-DTL-23053/16 equivalent to Raychem DR-25. It has the same 2:1 shrink ratio, the same −75°C to +150°C operating range, and the same chemical resistance profile. Mixing Deray V25 and DR-25 on the same harness is acceptable from a mechanical standpoint.

One consideration when substituting at connector backshell transitions: Raychem System 25 moulded boots are sized for the DR-25 wall profile at the boot entry bore. Verify dimensional compatibility before using Deray V25 under a Raychem boot at a sealed transition.

XTRA Motorsport stocks Deray V25 3/16″ and Deray V25 3/4″ as in-stock alternatives.

Raychem System 25

DR-25 forms the outer jacketing of the Raychem System 25 fully sealed wiring system. The complete system:

Ordering Notes

Per metre: Ordering by the metre gives one continuous cut length — not separate pieces. 5 m ordered = one 5 m length.

Full spools: Factory spools are supplied wound. Spool lengths vary by size: 100 m for 1/8″–3/8″; 60 m for 1/2″–3/4″; 30 m for 1″.

FAQ

Can I use DR-25 over standard PVC-insulated wire?

No. DR-25 requires a minimum surface temperature of 175°C for full recovery. Standard PVC insulation begins to soften above approximately 105°C. DR-25 must be used with mil-spec wire: M22759/32 or M22759/16 (Spec 55 ETFE/Tefzel, rated to 200°C) or equivalent aerospace-rated wire with PTFE or ETFE insulation. Applying DR-25 over PVC wire will damage the insulation before the tubing has fully recovered.

How do I select the right DR-25 size for my harness?

Measure the outside diameter of the bundle before sleeving. Select the smallest DR-25 size whose supplied (pre-shrink) inner diameter slides over the bundle without force. The size selection guide above lists typical wire counts for each size. For a reliable grip after recovery, the recovered inner diameter should be equal to or slightly smaller than the bundle OD — so choosing one size too large will leave the tubing loose rather than firmly jacketed.

What is DR-25-TW and when should I use it instead of standard DR-25?

DR-25-TW is the thin-wall variant of DR-25. It meets MIL-DTL-23053/16 and has the same chemical resistance and temperature range as standard DR-25, but uses a thinner wall for approximately 30% lower mass per metre. The standard DR-25 provides better abrasion resistance. DR-25-TW is used in F1, endurance racing, and aerospace applications where a weight budget applies. XTRA Motorsport does not hold DR-25-TW in stock — available on request.

Will DR-25 shrink lengthwise as well as radially?

Yes. Per TE Connectivity specification RK 6008/1, longitudinal shrinkage can be up to 10% of the sleeved length. For a 500 mm run, allow up to 50 mm of shortening. Pre-cut lengths slightly longer than the finished dimension, and route the harness fully before applying heat.

Is Deray V25 a direct drop-in alternative to Raychem DR-25?

Yes, for most motorsport applications. Deray V25 meets MIL-DTL-23053/16 and has the same 2:1 shrink ratio and −75°C to +150°C operating range. Mixing Deray V25 and DR-25 on the same harness is mechanically acceptable. If using Raychem System 25 moulded boots at connector backshell transitions, verify the boot entry bore ID against the Deray V25 wall thickness before substituting. XTRA Motorsport stocks Deray V25 in 3/16″ and 3/4″ sizes.

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