Advice on soldering multiple wires into one?

[EdwardNY]

When I made my last harness for a 12s4p pack us 6s turnigy batteries, I had to join 4 wires into 1 wire. I just stripped the ends on all 5 wires and then swirled the 4 wires into the 1 wire and put alot of solder to hold everything together.

I am not sure if this is the best way to do this. I was wondering if this way is OK or if there is a better way.

 

[mark5]

When I made my last harness for a 12s4p pack us 6s turnigy batteries, I had to join 4 wires into 1 wire. I just stripped the ends on all 5 wires and then swirled the 4 wires into the 1 wire and put alot of solder to hold everything together.

I am not sure if this is the best way to do this. I was wondering if this way is OK or if there is a better way.

Various ways used by people here:

Soldered wire Y-joints for paralleling by ryan and hjns:
http://endless-sphere.com/forums/viewtopic.php?f=3&t=33337&p=531087#p531060
ryan used 8 mm bullets
http://endless-sphere.com/forums/viewtopic.php?f=3&t=33337&p=531087#p530511
http://endless-sphere.com/forums/viewtopic.php?p=477008#p477008
http://endless-sphere.com/forums/viewtopic.php?f=3&t=31161&start=45#p477274
Ypedal uses a cut piece of thin copper sheet to bind wires for soldering:
http://endless-sphere.com/forums/viewtopic.php?f=4&t=31480&start=30#p457792

El_Steak uses an ANL fuse to parallel wires
El_Steak: Re: Parallel wiring harness
http://endless-sphere.com/forums/viewtopic.php?f=14&t=22454#p327340

GMUseless buss-style
http://endless-sphere.com/forums/viewtopic.php?f=3&t=31506&start=45#p479514
http://endless-sphere.com/forums/viewtopic.php?f=3&t=41150&p=601929#p601892

 

[cal3thousand]

The best way to join that many wires would be to crimp them. Otherwise, if you don't have access to that and can only solder, make sure to wrap the wires with a copper strand to hold them together. Then heat up and let the solder wick into the bundle.

 

[Punx0r]

Perhaps a solder pot (improvised) would make it easy?

 

[Kingfish]

+1 to the last two replies.

One method I have used for years is to organized the the group side (lets call it the Right side) and hold it in place with a drop of crazyglue. Insert the Left side single wire; I have a clip arrangement that holds the two together; not fun but it works. Then I take a single strand of wire about 6 inches long and thread it through, then wrap the entire assembly round and round. This gets soldered together. The wire wrap ensures the solder travels around the whole assembly. It's tedious as hell, but wicked strong.

A few weeks ago I traded that whole method away for swaging using copper tubing. Still a PITA to assemble, but definitely a whole lot faster. Cut off a 1/2 inch long peice of tubing, stick the wires in, give it a good crush with a hydraulic crimper, heat shrink to cover it. Less than 5 minutes - Done. Next...

The best part is: Conductivity is better because it's all copper and no solder.

Ref: Mechanical Crimping Large Gauge Wiring Harnesses
and Main power connectors - help please

Good hunting, KF

 

[adrian_sm]

When I made my last harness for a 12s4p pack us 6s turnigy batteries, I had to join 4 wires into 1 wire. I just stripped the ends on all 5 wires and then swirled the 4 wires into the 1 wire and put alot of solder to hold everything together.

I am not sure if this is the best way to do this. I was wondering if this way is OK or if there is a better way.

Just buy a harness already made for $13, 12AWG/10AWG

http://www.progressiverc.com/parallel-6x-hxt-4mm-bullet-charge-cable.html

 

[GCinDC]

just for the record, how about wire nuts?

 

[Ypedal]

http://www.youtube.com/watch?v=vPwFcIcAxhs&list=UUJCgYcCXBAuxEgVT1bpMnyQ&index=8&feature=plcp

[youtube]vPwFcIcAxhs[/youtube]

 

[dogman dan]

Wire nuts can work, particularly with just two or three wires to join, but aren't as good as a nice crimp. I like to make Y harnesses using a thing in the hardware store electrical section called a crimp sleeve. It's just a short piece of copper tube, like 3/8" or so, and half an inch long. Like the wire nuts, good for a few wires, 2-4 being joined, but not for 6-8.

 

[EdwardNY]

I was thinking about making another harness using 12AWG wire to a main battery line which will be 10AWG.

I was wondering if there is any problem with using 12AWG for this? The battery packs use 10AWG wire but I do not think such a thick wire is needed for the whole parallel harness.

To give an example of what I mean, all my batteries will be connected in a series using the batteries 10awg wire. But connecting each of these 12s lipos (2 6s packs) will use 12awg wire that will connect to a 10awg wire.

The reason I want to use 12awg ist he 4mm bullets can not fit on 10AWG without drilling them out which cause the connector to easily come out of the plastic housing.

 

[dogman dan]

I would say 12 g should be fine. With a bunch of packs paralelled, the amps flowing from each one gets less with each pack added. So two or more 12g connected to one 10g should work fine.

Up to 40 amps, I have just used 12 for everything. It does sometimes get warm, but not hot. At that power level, the rides pretty short anyway. So it's not heating up wire for hours or anything. But you would be right to go to 10 or more guage if you are playing with real power.

This link will show how I use the crimp sleeves towards the end of the article.

http://www.electricbike.com/crimp-anderson/

 

[EdwardNY]

Where do you buy your wire and connectors if you need to by them in the USA?

How long does hobbyking shipping take when using their cheap shipping?

 

[dogman dan]

EP Buddy is a good source for that stuff. Wire, bullets, Jst extensions, etc. No doubt there are other hobby shops that also ship fast from the USA.

Powerwerks for anderson power poles, supposing you wanted some.

Generally HK will ship in stock items in a few weeks, but if they have your item at the USA warehouse, it comes faster.

 

[EdwardNY]

Its too bad but hobby king seems to not have much of anything in the US warehouse. They don't seem to have any type of connectors, wire etc.