master plug

[allnite4u]

It would sure be nice if I could connect all these wires and plugs into one nice plug.
Well actually put all the wires coming from the controller on one single MASTER plug.
then same with the batery which will plug into one part of the master plug and the speed contorller and brakes into one plug that goes right into the other part of the master plug.
that way I could remove the battery with just a realese one the book rack and unplug.

Or did I miss this conversation from b4 and its already done.


thanks
James

 

[Sacman]

Only reason (I see) to have a master plug is if you are planning to repeatedly take the controller on and off the bike. Are you planning on doing this? If you are why? Many of us here just mount the controller permanently on the bike where it can be well ventilated and cooled. Now taking the battery on and off (as you say you want todo) is more common.

Also, the only multi-conductor plugs I've seen only have connections for wiring of simmilar guage. In your case you want a connector that has 2 big battery connections for the battery wires and the rest smaller guage connections. II haven't seen any plugs available like that. But maybe someone has.

 

[set]

You can redo the connectors yourself. I am in the process of converting my connectors from crappy white plastic connectors to anderson power poles. These connectors are very high quality. They fit very tight, and the best part about them: you can connect them. Kinda like legos. each connector has 2 male and female sides which allows you to connect them from the sides and bottom. What's also great about them is 15, 30, and 45 amp use the same housing. I bought the west mountain radio APP crimpers which cost me close to 50 bucks but it was well work it. It made perfect crimps.

While posible with the andersons to make a master plug, I wouldn't recommend it.

 

[Sacman]

That looks really good set. Anderson Power Pole connectors are awesome. But he wasn't asking about just upgrading wires and plugs. He said he wanted ONE SINGLE MASTER PLUG.

Hey allnite4u, if you really want to minimize your connections and do it right, use Anderson connectors for your power wires (red and black) and use a 9 or 12 pin Molex connector for the rest of your wires.

 

[TylerDurden]

You can get or make a master-plug, but large multi-pin connectors can be a real PITA:
If they are tight enough to make good connections, they are hard to connect and disconnect
If they are loose enough to connect easily, they may conduct poorly

Big multis are expensive, and use locking rings or screws.

(You can scavenge them off of old military gear found at ham-radio festivals)

 

[Pete]

Mil type connectors are fantastic to work with and can be made with custom pin configurations. I usually just go browsing at work and grab whatever is close enough to do the job . Low connection forces, weatherproof and self locking ( depending on the series of connector )

I have not had a serious hunt for anywhere that will sell individual plugs, but I do remember one place that would custom configure plugs as required. No idea what the minimum order was though. Maybe there is enough demand for somebody like Justin to have a batch made up?

About the only down side to Mil type plugs is the tools required to work with them. New, sealed packages almost always come with one insert/removal tool for each size of pin. These are usually plastic and need to be treated very gently if you don't want to leave bits of broken tool inside the connector. There is a knack to seating the pins properly without busting the tool. The other tool is the crimping gear for the pins. THey really need to be crimped with the proper tools or you will have no end of trouble trying to seat the pins properly. It is possible to treat the pins as cups and solder them at a pinch.

 

[D-Man]

Never had connectors on mine. Never will.

 

[marty]

I also was having thoughts of a big connector for all the wires coming out of controller. Putting controller, DC/DC converters in a aluminum box. Bought these connectors.

Bulgin
FLEX CABLE CONNECTOR
25 pole PX0820/P

Bulgin
REAR PANEL MOUNTING CONNECTOR
25 pole PX0708/S/25

After much thought I have changed my mind and will use water tight cord grips.

Got to buy wire and some type of tubing? What type of tubing to pull wire through? Heat shrink? Will measure size, then buy cord grips.

Any one want to buy 25 pin Bulgin connectors? Will sell for 1/2 of what I pay. Got pins, sockets, special tools and every thing needed.

 

[TylerDurden]

After much thought I have changed my mind and will use water tight cord grips.

Care to share those thoughts, as to why?

 

[marty]

After much thought I have changed my mind and will use water tight cord grips.

Care to share those thoughts, as to why?

TylerDurden,
Will send you my thoughts by mental telepathy. Are you receiving?

Will have wires going between controller box and battery, motor, controller switch, lighting switch, lights, GPS, cycle analyst, and throttle. Thats 29 wires, different gauge sizes. Everything will have a connector in line. Do I need a second connector at controller box? At first I thought I did because all the cars, appliances, and electric stuff I have worked on usually has a separate wiring harness. Then I thought KISS = Keep It Simple Stupid.