Butt Solder demonstration process

jharrell3623

Butt Solder Process

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Do you have a recommendation on a wiring parts kit that comes with quality connections? Last time I tried this it was a disaster. I need to redo a connection that ended up looking like garbage.

TechnicalDisaster

Do you have a recommendation on a wiring parts kit that comes with quality connections? Last time I tried this it was a disaster. I need to redo a connection that ended up looking like garbage.

I bought mine at O’Reillys (local auto parts store) but I’m guessing they all come from the same factory… I had to learn how to use my crisper more effectively and harbor freight sells shrink tubing, which really improves to visual look of the installation

Bluestreak57

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Hmm working on it , will have something up soon and will change link , sorry , damn program is weird =/

Link updated will be up shortly sorry.

You can get heat shrink butt connector soldering connectors on amazon. Most are good quality. The key is to NOT twist the wires before you put them in the connector. You force the strands together in the middle so it inter-twines each strand from one wire , with the strands from the other. That way when you solder it with a heat gun , NOT actual fire. It melts the solder and the solder interlocks the two wires together. Then the heat shrink is also on amazon. Wirefly has great heat shrink at a 3 to 1 ratio and with adhesive built in which seals it completely. Make sure the heat shrink cut is longer than the connector.

jharrell3623

You can get heat shrink butt connector soldering connectors on amazon. Most are good quality. The key is to NOT twist the wires before you put them in the connector. You force the strands together in the middle so it inter-twines each strand from one wire , with the strands from the other. That way when you solder it with a heat gun , NOT actual fire. It melts the solder and the solder interlocks the two wires together. Then the heat shrink is also on amazon. Wirefly has great heat shrink at a 3 to 1 ratio and with adhesive built in which seals it completely. Make sure the heat shrink cut is longer than the connector.

Ah. I always twist the wires before I try to join them. Thanks for the advice.

So much better than my “Soldering to NASA Standard” in ‘84

TechnicalDisaster

Ah. I always twist the wires before I try to join them. Thanks for the advice.

Me, too…. Have always twisted wire…. Learned something from the master today

TechnicalDisaster

Ah. I always twist the wires before I try to join them. Thanks for the advice.

I just went and spent some $$ on the shrink butt connectors…. Thanks

Bluestreak57

I just went and spent some $$ on the shrink butt connectors…. Thanks

LOL I went down that rabbit hole as well. Thankfully we use all the spare parts I have for other things at work. So I contributed to the work force my left overs =P. They do work very well. If you twist the wires , the problem is you are essentially creating a tight space that solder and the heat has a rough time getting to. Essentially you need a lot of heat to penetrate with the solder deep into the wire which in turn burns through the heat shrink on the connector. On top of that , the only bond you will have is the outside edges of each wire , versus the way I do it which promotes the heat to reach the inner most strands and the solder to penetrate it all. Once it cools , its actually as durable as the wire itself if not stronger and better connected. Once its wrapped with good heat shrink, You have four holding positions , the heat shrunk butt connector , the solder to the wire , the heat shrink over the connector , and the adhesive lined heat shrink , making for a very solid and waterproof solution. Thank you for the kind words.

Much better with audio. I ordered some butt connectors and heat shrink. I’ll let you know how it goes.

I have a slew of Bronco Parts to install, but they’re all waiting on one or two little things. Sigh.

TechnicalDisaster

Much better with audio. I ordered some butt connectors and heat shrink. I’ll let you know how it goes.

I have a slew of Bronco Parts to install, but they’re all waiting on one or two little things. Sigh.

Looking forward to it.

Thank you, was trying to figure this out the other day.

jharrell3623

You can get heat shrink butt connector soldering connectors on amazon. Most are good quality. The key is to NOT twist the wires before you put them in the connector. You force the strands together in the middle so it inter-twines each strand from one wire , with the strands from the other. That way when you solder it with a heat gun , NOT actual fire. It melts the solder and the solder interlocks the two wires together. Then the heat shrink is also on amazon. Wirefly has great heat shrink at a 3 to 1 ratio and with adhesive built in which seals it completely. Make sure the heat shrink cut is longer than the connector.

I’ve been using these for years on all my vehicles and trailers. Great connections that are weather proof. I haven’t done the non twisted wire though, I’ll give it a try on my next Bronco upgrade.

James M.

I’ve been using these for years on all my vehicles and trailers. Great connections that are weather proof. I haven’t done the non twisted wire though, I’ll give it a try on my next Bronco upgrade.

Awesome, yeah I tried it with twisting , the solder just never seemed to penetrate as well.

Eninty

All I saw was a hand...

Well I turn it and show it eventually.

I hate these things. They only work well on new wires. If you want to solder wires. Solder wires.

Good stuff @jharrell3623
A few additional wire management tips for a lifetime of trouble free DIY:
- use a larger diameter piece of heat shrink tube over the pair of wires to create essentially 1 single, double shielded and soldiered connection. (This will make the entire connection look factory fresh)
- allow additional wire for a small service loop at the end for any needed adjustments in the future
- use a good wire loom over the entire length of added wires to prevent any chafing
- use Tesa cloth tape to affix your new wire to existing factory wires so they are all routed and secure along factory wire paths
- lastly, snug down wires with zip ties (not gorilla tightened and pinching the wires) where appropriate to ensure the added wires stay put and don’t interfere with any moving parts when not affixed to any adjacent factory wires.