Tin a copper terminal

[waynieZ]

Hi guys, I need to tin a copper terminal I’m going to use flux and solder, because it being copper. I have tinning flux but I figure I don’t need it. Wiring gurus welcome to join in!

[572Camaro]

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

[waynieZ]

Thanks Jim OCD is a good thing. I suffer from NTMI never too much information. Thanks again. Wayne

[CamaroAJ]

Why are you soldering a terminal? I know there are people who think its the best, but soldering turns a flexible wire into a hard wire that can break with enough movement. GM doesn't recommend solder joints except in very few cases, like air bag connectors. Almost every, if not every single terminal in you daily driver is just a crimp joint and will last 100's of thousands of miles so that should be more then good enough for a hot rod. Just some food for thought.

[minendrews68]

Originally Posted by CamaroAJ

Why are you soldering a terminal? I know there are people who think its the best, but soldering turns a flexible wire into a hard wire that can break with enough movement. GM doesn't recommend solder joints except in very few cases, like air bag connectors. Almost every, if not every single terminal in you daily driver is just a crimp joint and will last 100's of thousands of miles so that should be more then good enough for a hot rod. Just some food for thought.

I can't say anything, I solder almost everything on my Camaro. Never had any problems with it coming loose or breaking. I have crimped wires and not knowing crimped too aggressively and actually cut the wires into .