Butt Splicing

[SShep71]

I have had 2 sources on crimping vs. soldering.

First my father who was a lineman for Pennsylvania Power and Light for 30+ years. He and I built several projects together. He had told me to use a linesman twist on solid, or an interweave on staranded. Presolder when possible, and after solder to lightly coat with dielectric grease. Shrink wrap twice, once just big enough to reach from end to end on the non insulated part then once cooled to shrink wrap again over top of the first shrink wrap obviously covering more than just the soldered area.

Second, was my automotive electrical teacher in college. He had told us to solder wherever you can using the APPROPRIATE solder. Lineman twist when possible and interweave when possible. Also, NOT all solders are the same the tin/lead content is different in most solders. The question was brought us about resistance because of the solder. When measured with a good Fluke meter the amount of resistance was so minimal its not worth mentioning. The one improtant factor to consider is the location of the solder joint in relation to any bends, twists, mounting of the wire. Copper is malleable, solder isnt as malleable. Thus leading to failures of the solder when not done correctly.



Just two little hints, when you have to do electrical tests dont shove pins into the connectors on either side. Use a small needle and backprobe the wire by inserting it a small amount into the insulation. When you take it out put some RTV silicone over the hole. You dont wear out and make the connectors at teh ends of the wire loose their tightness that way. I have done it for years and have never had a problem! Some people dont like it, but to each their own!

Second, if you use the barrel connectors and splice with them. If you look at the inside of the connector there is a joint where the piece was rolled together. On your crimper pliers there is a male (plunger) and a female (die) the plunger should be aligend opposite the joint. The joint should be aligned with the female (die) side. This promotes the most clamping on the wores and helps the barrel connector retain its strength. Dont get gorilla on teh connector either, It is possible to over do it on barrel connectors. And last but not least, you should notice there are severl different colors. Each color has a wire size that is most effective, stick to it! The last place is to cheat and skip in your wiring and have to trace the mile of wires in your car for a short, or even worse an electrical fire!

Many of you a seasoned vets, some of you are just getting into this. I hope some of you got something from this!

-Shep