Project Journals > Wolvenar

Repairing / installing wire ends

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Wolvenar:
Well I tried it the crimped on way, and got burned.
It seems with crimped on connectors, it just does not work well in these conditions with high strand welding cable.
That ball looking thing is the corroded wire expanding the surrounding insulation


So I figured I will try another route.
I am cutting back the insulation to give some room to solder on these ends, heated and let it take flux, and then as much solder as the wire would wick.




Solder on the end,,



Add some silicone that's not (supposed to be) corrosive to copper


Put on a couple layers of heat shrink tubing.



Finished,, move onto the next.


The trouble with soldering  on and doing all this is, its very time consuming!!

bj:
  Time consuming for sure, but so is a failed connection.  I have been doing smaller stuff with
solder for a few years, and heat shrinking, but haven't tried the silicone trick.  I use the shrink
with the inner soft flow layer.  The silicone should provide a fool proof seal.
   I also would like to try that hydraulic crimper, but haven't ordered it yet.
   Time will tell, but it looks bullet proof.
   Thanks for the idea Wolv

Wolvenar:
My failed one had been done with a hydraulic crimper at a parts store in town.
Maybe the silicone and heat shrink could work with that method also?

The interesting thing is, every cable connection on the bank that was isolated because of this failed connection had corrosion.
None of the rest had any worth calling corrosion.

bj:
   It should, but after careful consideration of about 1 hour, ;D I think I will stick with the solder
method.  I will however try the silicone on a cable that needs replacing on my tractor.  This
should be a torture test, as the alt gets overzealous, and boils the battery a bit on occasion.
   Never eats the solder, just the copper beyond it.  Silicone, and long shrink might just do it.
   Previous history says it will only take about a year to find out.

ghurd:
That is about what I do.
I crimp the end onto the solder-wicked wire (no fancy crimper, just the big hole in standard pliars), then solder the end.  Probably doesn't help at all, but I do it anyway.

For the inexperienced, silicone and 'liquid tape' are flamable when wet.   ;)
G-

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