![]() These splices (four each minimum) were made using solder-seal butt connectors, crimp connectors, and conventional soldering technique, interlacing the wires before soldering. Twelve-inch test samples of 14-gauge and 24-gauge wire were assembled with a splice in the center. As a control, we also tested conventional crimp-on butt connectors applied with ratchet crimpers and unsupported electrical tin/lead solder. We selected an assortment of solder seal butt connectors from 3M and Electriduct Cable Management. Because there is no mechanical connection, they don’t meet the ABYC standard, but we wondered if they might help manage the proliferation of the small-gauge wires that electronics and LED lighting have spawned. They consist of a length of adhesive-lined heat-shrink tubing with a small ring of low melting point solder at the center. New on the DIY radar screen are solder-seal butt connectors. There are limited exceptions in the standard for battery lugs. The danger is that when overheated, the solder can melt and the heat-shrink tubing will soften, allowing the union to fail and the circuit to short.Īdditionally, PS testing has confirmed that soldering increases corrosion and decreases fatigue resistance by making the wire stiffer. Nevertheless, the American Boat and Yacht Council (ABYC) recommends that solder not be the sole means of connection. We’ve done some testing of solder connections and they can be very good. The are firm in their opinion that no other connection can be as reliable and corrosion proof. Some DIY sailors are addicted to soldering. Cheap buss bars have corroded away, but never one of our ratchet crimps. We’ve made countless thousands of crimps over the years, including hundreds for Practical Sailor salt spray chamber testing, and we’ve never had a failure. On the other hand, a properly adjusted ratchet crimper practically welds the fittings to the wires, and failures are scarce. They occasionally get a bad name from shoddy crimps made using vice grips or discount store plier-style crimpers. It is no wonder that marine electricians have high standards.Ĭrimp connectors are the gold standard. It is commonly estimated that over 90 percent of electrical failures on boats result from poor connections. ![]() The consequence of failure range from a light that doesn’t work to a fire that can cost lives.Ĭonnections must be physically strong to keep resistance low, and remain corrosion-free for a lifetime, enduring vibration and attack by heat and saltwater. A typical cruising boat has thousands of electrical connections.
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