Making Proper Wiring Connections

There Are Three Parts To An Electrical Connection... They are...

  • Mechanical Connection.
    This is the actual twisting of wires or crimping wires into a tube.
    This should NOT be confused with an electrical connection.
    When you are using 'Quick Connectors' (also called 'Crimp Connectors'), don't be fooled into believing these are enough to make a proper electrical connection.

    Simple crimp connections are dissimilar metals, and basic metallurgy will tell you dissimilar metals will corrode in a very short period of time.
    Add the fact that most crimp connectors trap moisture in the joint, and you have a failure waiting to happen!
    If you live in one of the states that uses salt or calcium chloride on the highways to melt snow, you will have a failure rate of nearly 100%.

  • Electrical Connection.
    Solder is the only practical way to make an acceptable electrical connection.
    NO ACID CORE SOLDER EVER! Acid will eat away at the copper in the electrical joint.
    Use only rosin core solder, and if you can find it, use an electrical mixed solder with silver content. (Radio Shack)
    The silver will help electron flow, bonding and with environmental protection.

  • Electrical Insulation, Environmental Protection
    If the joint is never going to see 'outside' moisture or the elements, the old black tape is probably good enough.
    If you are making electrical connections on a vehicle, use heat shrink or cold shrink tubing with a glue sealer.
    There are some liquid vinyl 'paint on' insulations, and I've seen them do a good job when the surfaces were good and clean.

    If you are using virgin copper wire (not alloy wire, and lots of wire is alloy these days) and solid copper terminals, you can actually crimp (mash) the connection hard enough the copper will bond with it's self and not require the soldier.
    This much pressure takes a special crimper, requires some training, and is limited to large connections, like battery cables.
    Once crimped, you can cut apart the connection, and the copper will be one solid block with no seams.
    This doesn't rule out the environmental protection and electrical insulation!
    You will have to keep the moisture (and environmental pollutants) out of the joint.

    Once you acquire the tools, and learn to do the connections correctly, you will find electrical problems going the way of 'Magnetos' and 'Bias Ply' Tires...