best method to splice power wires when messing with battery discharge connector.

[derekderek]

probably among the most common things us DIY types do. and one with the best chance of really bad results. i have had some luck with those clear heat shrink tubes with ring of solder in em. not crazy about but it works. i also tape on top of the heat shrink and add a slit open heat shrink tube slipped on 1 wire and between both wires and tape the whole mess together. and i also add a fuse holder and fuse right in front of discharge connector if i am in there. then you can work on 2 wires a half inch apart without risking fireworks. but i am sure there are better ways and probably a considered best way to do this. thanks for insight.

 

[scianiac]

I mean kinda depends on various factors, how much current are we talking, how big are the wires, how waterproof does it need to be. The best way and honestly it's pretty easy once you do it a few times is a quality butt crimp connector that is well crimped. And those depend on how much current and wire size. For small wires and low current quality butt crimps and hand crimpers work but for larger stuff I use heavy bare butt crimps and a hydraulic crimper then seal with some adhesive lined heatshrink for a clean and decently water resistant result.

What's annoying is areas where you can't easily use heatshrink which is where I use rubber splicing tape or if it's two wires into one I use the heatshrink but fill the gap that is left with some adhesive, you can hot glue between the wires and then that melts into the hot glue inside the heatshrink when you shrink it. Also use silicone or polyurethane sealant for instance to fill the backsides of connectors that are often open.

 

[docw009]

I used to take the metal core out of a larger crimp and use it as a form to join battery wires with solder. Put heat shrink over it. Now I use the nickel spot weld strips from my battery hobby, Roll those in a cylinder and stick the wires in it. You need two extra arms, which is where I use the stand with the alligator clamps.

Example on a 9 pin motor cable. If I space the joints, the spliced cable still slides thru a 12mm hex nut,

 

[derekderek]

spacing joints also protects against fireworks if insulation is suboptimal.