Best Connections?

[deronmoped]

I was looking at the connections on the controller I just bought and thought that they were a problem just waiting to happen on the high amperage ones. Being a electrician and finding 99% of the problems I encounter are bad connections, I'm ready to get rid of the connectors that came with the controller. I would either solder them or use a soldered eyes with a bolt.

Any suggestions?

Deron.

 

[nicobie]

I really like Dean's connectors. To me Anderson's are a pain in the A** and are kinda big too.

Nick

 

[Drunkskunk]

60% of this forum probably will recomend Andersons.
The other 40% know how much supperior Deans are

 

[Kurt]

+One one the Deans ultra plugs such a simple design A very tight compact and low resistance connection. Like most good plugs its idiot proof and cant be plugged in backwards.

In a 100% perfect world I would like to see a larger version of the deans plug for the very heavy gage wires.But for most e bikes there more than adequate.

They are available through most online Rc hobby stores or some electronic supply stores. for around $2 a set. You simply tin then solder you wires to the small stubs then slip some heat shrink over each wire and then a large heat shrink over both wires and most of the plug.

Kurt.
Deans ultra plug set

 

[northernmike]

Castle Creations "Bullet" conectors - 6.5mm, 200A rated.

If your needs are greater,

I'm apprenticing myself, and totally share your concerns! Though I've used Deans on many R/C vehicles, that was with max. 10 AWG.

My power system's next iteration will be using #4 stranded copper - scraps from the feeds for the elevator motors in the condo I'm working at!

Look to the Alltrax / Curtis / Sevcon stuff of E-Motorcycle use - big power gets big connections.

 

[deronmoped]

All these connectors have to deal with the weather too. Corrosion is going to happen, may take a few years, but it will have you scratching your head wondering what went wrong. Most of the time I make connections permanent with solder, but if I need to use a connector I put some sort of anti-corrosion compound on it.

Those Dean connectors look pretty good, how does the plastic hold up against the heat of soldering it?

Deron.

 

[nicobie]

Those Dean connectors look pretty good, how does the plastic hold up against the heat of soldering it?

Deron.

No problems at all if done right. You need to tin both the wire and the tab, then join them with a decent sized soldering iron. This takes about 2 seconds. Try not to over heat the joint and don't solder with 2 connectors plugged into each other. These are good for up to 10g wire.

 

[dnmun]

can't believe i am agreeing with deron.

go with soldered connections, everywhere.

put a small switch on your controller current and leave the entire bike intact and charge while the pack is on the bike.

solder in a small inline circuit breaker sized to suit your personality and controller. then you always have a mainline switch by throwing the breaker manually.

but you knew this already if you are an electrician.