Good Connections PART 2
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- Clementine Beasley
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1 THE INSTALLER SERIES by Steve Bodofsky Good Connections PART 2 Figure 1: You can improve the quality and longevity of a butt connector by sealing the ends, either with RTV, or by using a connector designed with heat shrink insulation. Now that t you ve e found f a bad connector or,, what s s the t best t wayw to o replace r it? Solder and shrink tubing. In the last issue of GEARS, we discussed the importance of checking the electrical connectors. We learned what to look for, where to find new connectors, and how to replace them using typical friction connectors; that is, wire taps or butt connectors. But we also learned that these connectors aren t the best way to repair a wire. They add resistance to the circuit, and will degrade over time, as water, oil and dirt find their way into the harness. You can improve these connections by sealing them against the weather (figure 1). Butt connectors are available with heat shrink insulation: Just heat them up after crimping, and the insulation shrinks down to seal the connection against the elements. Or you can use a dab of RTV sealant on either end of a standard butt connector. Either technique will extend the life of the connection dramatically. A wire tap is a harder to seal, but it can be done with a little extra effort. However, the best type of repair is still the old-fashioned way: solder. Solder encases the ends of the wires in a solid layer of lead and tin, to provide a better connection, and to prevent wear between the two wires. And by using a piece of shrink tubing to seal the wire, you end up with a weatherproof seal on a quality connection a connection that s more likely to stand up to the test of time. So let s look at how to repair a harness using solder and shrink tubing. These procedures are for soldering copper, multiple-strand wire the most common type of wire on today s cars and trucks. If you find yourself working on an aluminum wire, forget about solder: It won t hold onto the wire. In that case, either replace the wire completely, or you ll have to use a friction connector. Figure 2: To solder an electrical connection, you ll need a soldering gun, a roll of rosin-core solder, and an assortment of shrink tubing. Solder Connections For a solder repair, you ll need a few simple things (figure 2): A soldering gun or soldering iron in most cases, the quickest and easiest tool is a soldering gun that develops about 40 watts of heat. Rosin core solder this is the preferred type of solder for soldering copper wires. 28 GEARS September 2002
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4 Figure 5: Strip about 1/2" to 5/8" insulation on each end of the wire. Figure 6: Slide the shrink tubing over the end of one of the wires. Do it now! After the repair will be too late. the smallest tubing that will fit comfortably over the wire. But if you aren t sure whether you have the right shrink tubing for the wire size, test it: Cut a little piece, and shrink it down onto a piece of scrap wire. If the tubing shrinks all the way down against the wire insulation, it ll work fine for the repair. Okay, let s begin: Cut a piece of shrink tubing about 1 to 1 1/2 in length. You ll want to use tubing that fits easily over the insulation, without being too big to shrink down to size (figure 4). Strip about 1/2 to 5/8 of insulation from the end of each wire (figure 5). Slide the shrink tubing over the end of one wire. Use an alligator clip from a jumper wire (or your Helping Hands) to hold the shrink tubing out of the way (figure 6). (Continued on page 34) GEARS September
5 Good Connections, PART 2 (Continued from page 31) Figure 7: Mount the wires into your "helping hands", with about a 1/2" overlap. Use one of the clips to hold the shrink tubing out of the way. Figure 8: Bend the ends of the wire up, so the bends are halfway between the insulation and the bend on the other wire. Figure 9: Twist the wires together, to form a nice, tight connection. Figure 10: Apply the tip of your soldering gun to heat the wire joint. Don t apply the solder yet. Bend the stripped ends to about 90º (figure 7). Overlap the wires, so the bent ends about halfway between each other and the insulation (figure 8). Twist the ends of the wire around each other, to provide a tight, twisted connection without becoming much thicker than the rest of the wire (figure 9). Apply the end of the soldering tip to the wire, and pull the trigger. Heat the wire for a few seconds (figure 10). Figure 11: Once the wire heats up, apply the solder to the wire, and let it melt into the connection. Apply the solder to the wire, near the soldering tip. The solder should melt and flow into the wire (figure 11). 34 GEARS September 2002
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7 Good Connections, PART 2 Figure 12: Make sure the entire connection is coated with solder, then let it cool. Never try to apply the shrink tubing to a hot connection. Figure 13: Once the connection is cool, slide the shrink tubing so that it s centered over the connection. Figure 14: Use your shop heat gun to heat the shrink tubing, and shrink it all the way down onto the repair and the insulation. Make sure you get solder all the way through and on all sides of the connection. If the solder gets too heavy and it starts dripping off, flick the connection gently with the soldering tip or a small screwdriver while it s still in a liquid state. That should knock the excess solder off (figure 12). Let the connection cool. Never try to apply heat shrink tubing to a hot connection: The tubing will melt and expose the wire. Once the connection has cooled, slide the shrink tubing down over the wire repair (figure 13). Heat the wire evenly, until it shrinks down tightly over the repair (figure 14). The best way to heat the tubing is to use a heat gun, rather than a match or lighter; the heat gun provides a more even heat, and won t melt the tubing. Repeat the procedure for all the connectors. Once you have the repairs made, use a plastic conduit or electrical tape to restore the harness to its original appearance. That s all there is to it. Make sure you keep track of your time, and any parts or supplies you use for the repair. These repairs should be added to the final cost of the job. And save the damaged connector: It can be a great visual aid for demonstrating the need for the additional repair to the customer. 36 GEARS September 2002
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