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Old 10-09-2019, 10:07 AM
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572Camaro 572Camaro is offline
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Assuming you are attaching a terminal to a copper wire,
here is the process I used on my car, which is the exact process I learned by attending training from my local nuclear plant controls technician:

1. Strip wire end long enough so you have 1/16” or so exposed on back side of terminal.

2. Tin the wire end by using flux and a GOOD hot soldering iron. Just practice so you don’t get the copper wire overheated unnecessarily.

3. Crimp the terminal end using proper crimper tool.

4. Do a physical pull test, about five pounds of pull to ensure terminal is secure

5. Now take your wire/terminal and resolder carefully by adding just a little solder on the back side of the terminal. That is why step one has you keep 1/16” exposure of copper.

6. Now shrink wrap by heat gun only and start at middle, then work to both ends.

I followed this procedure for every terminal on my car.

A few other thoughts:

Not all flux is acceptable for electrical wiring as it will cause corrosion.
Some flux is for copper plumbing only. So be careful.

Buy small wire diameter solder. I prefer 70/30 alloy blend.

There has been a debate for a long time as to wiring should be soldered or not.
Drag racers tend to just crimp and not solder due to concerns over brittle fatigue.
So expect other differing responses to this thread.

Here’s my two copper pennies worth:
Solder everything
Just don’t overheat the wire to the point of annealling the copper conductor.
And use shrink wrap to secure the “heat affected zone” of the wire to keep it from flexing.

I know, I know.., too long of a response..,
See, I suffer from OCD. (Obsessive Camaro Disorder)

Jim
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