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As some of you know, I rewired the old IM when I rebuilt it, and then did a major cleanup and documentation of the first wiring job a couple of years later. I made a mistake...

I used to be a research lab electronics technician and ran a small research electronics company. Wire wrap and solder were the way I did business.

Cars are different. Things move and vibrate, the rain and the sun get in, it isn't exactly laboratory conditions.

I read up on car wiring and saw that I would have to use crimp connectors and lots of shrink tube. Eventually I got the tools and supplies needed and got the hang of making good crimps.

However, the very first thing I wired into the car, even before I put the body back on the chassis, was a big air conditioning condenser and fan. It fills the space between the firewall and the rear seat. In my eagerness to 'git r done' I didn't wait for my crimping stuff to arrive. I used soldering and electrician's tape to attach the fan wires. In my rewiring effort, I didn't remember that mistake. Out of sight, out of mind.

Recently the AC stopped cooling. After recharging the system (it didn't need it), pulling relays, and fuses (blown) it was obvious that the fan was the culprit. One of the solder connections had a sharp edge that had worn through the insulating tape creating a short circuit.

It was easy to cut out and rewire, but it seemed like a good cautionary tale for folks doing a little fixing or addition to their wiring.

TLDR - use crimps, automotive rated wires, and shrink tubing. It will save you or someone else a pain-in-the-butt experience later on. I bet @DannyP will back me up on this wisdom...

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I’m a “belts and suspenders” guy. I like to crimp and solder.
Today, Ideal and Thomas and Betts both make really cool heat-shrinking Sta-Cons. Soldering the crimp also does the heat shrinking. If you don’t use those, at least use the nylon-insulated ones. The cheap plastic ones aren’t worth the shipping cost.


One last tip: Use a good contact cleaner/coating every time you make/unmake an electrical connector.  It cuts down on issues by at least 75%.  I prefer Craig deOxit Gold G5.  A little bottle like this is a lifetime supply.

Amazon also has a kit of Craig products that’s pretty handy, too.

IMG_1294

The D series (red) stuff is good, too. But I think the Gold (G Series) protection lasts longer.  As you can see, I bought this kit in 2015 and I’m barely 1/4 of the way through it. (But, full disclosure, I had a can of aerosol in my work box when I retired which I often use)

ps: I retired in 2013 so, like I said, the stuff goes a looong way  

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Last edited by dlearl476

Every once in a great while I'll buy a kit of different size/color shrink tube from Amazon.  The stuff is great.  I also have several different color rolls of 3/4" - 1-1/4" shrink tube that was trashed at work.  About every seven years it comes in handy.  If it looks like the connection will be in a really abusive location, I'll often double shrink it with two different sizes of the stuff, just to make sure it's good.

If I'm connecting wires in a harsh environment (read that out near the wheels) I'll usually crimp the connection with a shrink tube over it, fill the ends of the tube with silicon caulk and then shrink it.  Never had one fail, yet, it 20+ years.  Sometimes I solder a connection, if it makes more sense than crimping, but still use the shrink tube and silicon caulk - Belt and Suspenders (or Braces, if you're British).  

In the end, nothing short of a weather/environment proof MOLEX-style connection is good enough, but I'm too cheap to spend that kind of money on a car (even if Honda and Subaru do that all the time).  Shrink tube and silicon caulk is a lot cheaper than a military-grade Molex or AMP connector, for sure.

I remember Ron, our AMP Connector sales rep at one of the computer companies I was at.  Back in the early 1980's the guy had his own Lear Jet.  That must tell you something.

I really try to NOT solder anything in the car these days. Sometimes you have to, but it is better if you don't. Vibration, corrosion and metal fatigue are the reasons.

I've stripped Subaru harnesses a couple times. They crimp everything. Under all the insulation and tape, there are MANY butt splices and ground crimps for a pigtail here and there. None of them were bad, they all were strong and not corroded.

I also try to never use tape, preferring heat shrink as much as possible instead. But this requires a lot of planning ahead with respect to wire length, room to slide the heat shrink, and sometimes staggering connections so the whole bundle doesn't get too fat.

When I do solder, I use marine heat shrink(mostly from Harbor Freight), which has a clear goo coating inside that seals around the wire insulation when heated. I also support the splice on both ends to something solid so vibration can't happen. Pretty much the only place I solder is to butt splice wires. And I really can't stress the support thing. If you immobilize the joint, it goes a long way to making it survive.

I have seen MANY of those solder/heat shrink combo connectors fail that Alan talks about. In my mind, they are junk. I have no idea what solder is used inside, but it appears to be a low enough temperature that they always corrode. I don't think any moisture gets driven out, hence they corrode and fracture. I know people use them with seeming success, but let us see how they fare in 5 years.

Harbor freight sells 4 foot lengths of multiple diameters of heat shrink for a low, low price. It comes in 6 or 7 little white boxes that are clear shrink-wrapped together. These are easily overlooked on the shelf in the store. This is what I used to make my EFI harness. Each box contains a 4 foot coil in a different size. Handy, for sure. I cut pieces of 18 or 24 inches. More than that makes it impossible to slide the wires through. I used a piece of MiG wire as a fish/pull. Overlap each joint by an inch, letting the first one cool before attempting to overlap the next one.

My best purchase ever for wiring was the three slot ratchet crimper on Amazon for 30 bucks or so, rather than the several hundred dollar Klein or the like. This crimper handled the large GM Weatherpack crimps of 14-16 gauge to the tiny ends on my ECU harness of 22-24-26 gauge. Practice first, and making strong and reliable crimps becomes easy.

I also purchased some 2 and 3 conductor connector pairs. Male and female plastic ends, silicon inserts, and metal crimps. These are pretty inexpensive Deutsch connector knock-offs, say less than 10 bucks for a dozen pairs. I used these on some aux gauges in my Cayman, replacing the horrid bullet connectors that the gauge came with. I also had to use these on the headlight wiring of my truck. The previous owner cut out the connectors that were there, and used those cheesy heat shrink/solder combos. Which failed, of course, even though no water sprays on them, they are behind the fender liner.

I picked up spade connectors(think Bosch blue coil) and ring connectors from Ace Hardware. These have nylon insulation and appear to be the same quality as Wurth. I always back up these crimps with heat shrink as a stress relief from the crimped area to the wire insulation.

And finally ALWAYS use grommets when passing through a bulkhead.

Plan ahead, use the right tools, and wiring is easy. Especially today, the cost of the right tools is not high. Maybe I'm a weirdo, but I enjoy this stuff.

Cheers.

Last edited by DannyP

We often read that crimp connector connections are junk but that depends on the quality of the crimping tool and the hands doing the job.  When I first tried the solder seal connectors they recommended a heat gun or BBQ lighter.  The heat gun, while it quickly shrinks each end of the connector, a heat gun takes a bit of time to melt the solder and produces a dull looking cold solder joint.....Not good.  But using a BBQ lighter you get fast and good solder joint. I like them but in places where water intrusion is known I add a piece of shrink wrap over that connection and as Danny said,  time will tell.

Last edited by Alan Merklin

Every once in a great while I'll buy a kit of different size/color shrink tube from Amazon.  The stuff is great.  I also have several different color rolls of 3/4" - 1-1/4" shrink tube that was trashed at work.  About every seven years it comes in handy.  If it looks like the connection will be in a really abusive location, I'll often double shrink it with two different sizes of the stuff, just to make sure it's good.

If I'm connecting wires in a harsh environment (read that out near the wheels) I'll usually crimp the connection with a shrink tube over it, fill the ends of the tube with silicon caulk and then shrink it.  Never had one fail, yet, it 20+ years.  Sometimes I solder a connection, if it makes more sense than crimping, but still use the shrink tube and silicon caulk - Belt and Suspenders (or Braces, if you're British).  

In the end, nothing short of a weather/environment proof MOLEX-style connection is good enough, but I'm too cheap to spend that kind of money on a car (even if Honda and Subaru do that all the time).  Shrink tube and silicon caulk is a lot cheaper than a military-grade Molex or AMP connector, for sure.

I remember Ron, our AMP Connector sales rep at one of the computer companies I was at.  Back in the early 1980's the guy had his own Lear Jet.  That must tell you something.

I guess he made a lot of connections

.

I'm lazy. For the most part, I crimp.

But, I'm also old and, harumph, there's nothing wrong with soldering, sonny — it's all in the technique.

It sounds to me like the solder joint didn't fail, but the tape did.

A properly done solder joint, besides being electrically sound, should also be mechanically clean, neat, and smoove. The tape is for insulating. It shouldn't be relied upon to do anything mechanically. And yes, shrink wrap is a hundred times more sturdy.

I got a 30-foot sailboat almost 20 years ago, and the instrument panel (in the cockpit and exposed to the marine environment) was a warren of daisy-chained crimp connections and screw-down terminals. The ground or power supply to any given instrument might have to jump through five other instruments, with two crimp connections and two screw terminals at each jump. On a boat — guaranteed disaster in the making.

I drew up a mini harness for the whole panel, soldered all the connections, and taped everything up nice and neat. Zero issues with anything in that panel, ever.

And, praise the Lord, we just sold the boat.

.

Mitch!   So you have finally escaped from that hole in the ocean that you continually poured money into?  Well Done!!!!!!!!!!

I’m of the camp that believes that crimping, properly done with the right terminals and a reasonably decent manual crimp tool, is perfectly OK.

We used literally hundreds of crimp connections in the computers we made, BUT, the wire size and type, the terminal size and type, and most importantly, the (pneumatic) crimper machine type AND crimp torque (force) were all specified by the design engineer and followed by the manufacturing engineer and the production floor.

We don’t have ANY of that when making a harness for a Speedster/MG/Spyder/etc.  We just wing it with educated guesses and hope for the best.  Most of the time our crimped connections are OK for as long as we own the car (20 years for me, so far) but we don’t usually drive in rain so the crimp connections will be OK for a lot longer.  Getting exposed crimp connections wet now and then accelerates corrosion unless the connections are protected as people have mentioned up above.  This is because you have copper or tinned copper wire making direct connection with a steel crimp barrel.  The dissimilar metals (copper and steel) don’t like each other chemically and the corrosion is accelerated by water.  The way to make them last longer is to protect the connections from water intrusion.  A little extra effort to insulate while crimping can mean years longer service life.

Last edited by Gordon Nichols
@IaM-Ray posted:

It is said that the two best days of boat ownership is the day you buy it and the day you sell it.

I understand the saying but as someone who currently owns a ski boat, a fishing boat (Zodiac perfect for diving and toddlers too), two canoes including a 1940 Peterborough cedar strip, a paddle boat, 4 kayaks, a Laser sailboat, a double ended hand made rowing skiff and three paddle boards and currently at the cottage enjoying them all, I disagree!

They all fit in one boathouse and all my kids (and now grand kids) are water/boat people. I will always live on water and always have a boat, in fact we're potentially moving .... to a lake

@ALB posted:

Getting back to the original topic- as I'm not the most knowledgeable when it comes to electrical stuff- after crimping would there be a benefit to putting a drop of dielectric grease on a connection and then covering with heat shrink tubing?

I use a tube of Dow Corning MolyKote 4 and stick the stripped ends of the wires into the tube to coat them BEFORE I crimp and heat shrink. Since the connection is mechanical, the dielectric grease doesn't create a problem and protects the connection inside the crimp. No data on this, just my approach...

We wire stuff every day, and I’ve always marveled at the lengths people on automotive websites go to with solder, etc. I’ve never understood why, except that perhaps being retired makes people look for hard ways to do easy things.

Refrigeration compressors shake like paint mixers, and we never use anything besides red, blue, or yellow jacketed crimp terminals. T&B is nice, but I’ve not noticed enough difference to warrant the 10x price difference between them and the 100 packs of house-brand terminals at the refrigeration supplyhouse.

On the car, when I need it to look nice, I pull the jacket off the terminals I carry on my truck anyhow, and use HarborFreight shrink-tube instead. I’m unconvinced it makes a bit of difference, but I do it so it looks pretty (the blue and red jackets look pretty tacky). I put a dab of silicone on any screw terminals outside the car, but inside - I just schlep along exposed to whatever moisture is under the dash (which is to say, the humidity in the air). For reference, your switches and gauges are open as well.

I crimp with a good forged Ideal or Klein crimp tool (not the stamped steel combo strip/crimp pieces of garbage sold everywhere). A Klein T-Stripper tool for everything from 10 ga to 20 ga is 10 bucks, but the crimp tool is at least $40, and worth every penny. I won’t attempt a crimp with anything else (I carry a spare on my truck, because I can’t be without).

It’s the automotive style connectors we never use on the jobsite that I need to be brought up to speed on. @DannyP makes reference to generic crimp tools and copy connectors on Amazon. Any links would be appreciated.

Last edited by Stan Galat
@Stan Galat posted:

It’s the automotive style connectors we never use on the jobsite that I need to be brought up to speed on. @DannyP makes reference to generic crimp tools and copy connectors on Amazon. Any links would be appreciated.

Danny and I like the Deutsch style connectors for general use. I like to divide my wiring up into branches and put a connector on each branch. I run a lot of sensor, power, and ground wires to the engine, so I like to put a big bulkhead connector on the firewall. I then run branches to the throttle bodies, fuel injectors, ignition module, etc. Each of these branches has a Deutsch style connector close to the terminations to make it easy to drop the engine and troubleshoot potential problems later. Where it makes sense, I put individual, insulated, spade connectors for fast disconnections.

I've got a variety of crimp tools. For butt connections I just use the cheap crimpers that come with the kits (with red, blue, yellow notches). For connector pin crimps I've cycled through a few higher end (but not brand name) crimpers made specifically for doing the initial pin crimp and then the insulation crimp. They still take a lot of attention to make them sturdy and pretty (yeah, I know, not a measurable thing).

Label wires and bundles while you're in there. I use an inexpensive label printer that can do ribbon labels for big bundles and heat shrink labels for individual wires. Document everything as you go (e.g. source, wire gauge & color, bundle, pin# on destination connector (and connector type/size).

Links to things I like:

Big Bulkhead Connector: https://www.amazon.com/gp/product/B01H8LKF3U

Deutsch Style Kits: https://www.amazon.com/gp/product/B07L9XNFGG

Insulated Spade Connectors: https://www.amazon.com/gp/product/B00SUTYYS2

Relay/Fuse Box: https://www.amazon.com/gp/product/B07MR64XK1

Relay Box Spare Connectors: https://www.amazon.com/gp/product/B01MFEDLM4

Dymo Label Maker: https://www.amazon.com/gp/product/B005X9VZ70

Cheap Ribbon Labels: https://www.amazon.com/gp/product/B07T8D6K2Z

Cheap 1/2" Shrink Labels: https://www.amazon.com/gp/product/B07J3KJ9GX

Cheap 1/4" Shrink Labels: https://www.amazon.com/gp/product/B07NZ51DQC

@DannyP usually has a good vendor for automotive bulk wire. I usually use TXL style and various sizes depending on what it is for (20 ga and above is fine for sensors). Sometimes I split a wire into two wires to go through a connector to make sure the pins will handle total amperage and recombine the wires after the connector (e.g. ignition module, AC clutch, big fans). I put fuses before the relays. If you are using an ECU, use star grounds running back to a single ECU ground. Grounding and electronic interference are big ECU issues. Contact me if you need guidance.

Last edited by Michael Pickett

Besides a variety of Ideal crimpers that I accumulated over the years, I also ended up with a Brady labeler. (I still can’t believe no one on the show wanted it. I had to fight like hell to get Disney to pay for it)

I love these little tape+labels. Put a bit of clear heat shrink over it and it’s good for life. (Although totally not necessary. My spark plug wire labels are still good all by themselves after 6-7 years)

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