I've spent weeks trying every combination of places for my C-points, number of C-points per connector, manually defining wires, using from-to lists, but my route subassembly gets huge (>25MB) and it takes forever to edit the route (10-30 seconds per change in spline properties).

Additionally, SolidWorks crashes, says it cannot flatten the route, magically deletes connectors from the routs, moves fully-defined connectors around, and can't find from/to components in the route subassembly.

When I do get lucky enough for a route to flatten, wires and pinouts are missing (connectors all by themselves on the drawing).

Has anyone been able to make a moderatley complex harness and get it to flatten without crashing solidoworks and have a flattened route that is correct?

BTW, the harness I want to make has 65 wires, 13 connectors and 26 wires that attach to screw terminals on PCBs. I am using SW 2009 SP 3.0