Weather Proofing Deans Ultra Plugs

[solracotos]

Quick Question! I have a couple of exposed Deans Ultra Plugs(T-Plugs) that connect my battery pack to Watt Meter, and Watt Meter to Controller. Since those connections are exposed to the elements. I'm afraid that rain may cause a short.

What do you suggest for Weather-Proofing those connections that would still allow me to connect/disconnect these plugs easily a couple times a day?

Solrac

 

[dogman dan]

Silicone tape comes to mind. Justin has or had it on the ebikes-ca site. Nowdays you see tv commercials for it, so it may be in lots of stores now.

Another option might be some kind of merely water resistant method, like a small box that can be opened, with the connector inside. Using a drip loop, the box at the top so no water drips down the wire etc.

Easy for permanent connetions, Special caulk for rain gutters is the bomb for permanent sealing. Sticks to everything best of any sealer.

 

[icecube57]

Heatshrink and dielectric grease.

 

[solracotos]

All of these solutions except for the box are a bit permanent and not suitable for a connection that has to be made/undone at least twice a day.
Thanks for the suggestions.

 

[liveforphysics]

Smear a bit of vasoline (or dialectic grease) in the female side. Problem solved.

 

[Drunkskunk]

Dielectric grease and I coat the solder side with epoxy

 

[spinningmagnets]

As long as we're on this general subject, whats a good non-conducting potting compound, and whats a good web-supplier to order it from?

Also, is there such a thing as an epoxy that conducts well? perhaps for attaching tabs to cylindrical cell-ends without soldering or spot-welding?

 

[Drunkskunk]

http://www.thinkgeek.com/gadgets/b70c/

Wire glue. But it's carbon based glue, so not good for high current circuits like batteries.

I pot everything in Epoxy or not at all.

 

[oldpiper]

Also, is there such a thing as an epoxy that conducts well? perhaps for attaching tabs to cylindrical cell-ends without soldering or spot-welding?

There is conductive epoxy, which contains silver, but I don't know offhand just how low its resistance is.

Cameron

 

[liveforphysics]

All conductive epoxies are awful conductors.

 

[dogman dan]

the silicone tape is not sticky back. It just grabs from stretching so It could be undone easy. Then there's the ol scrap of inner tube trick. It would be oriented to cover one side, and have the more open side down. Slide it up, to uncover the wire.

Or do like I have, locate said connection under your ass, where if you use a rear fender, stays pretty dry. Can bag the seat when parked.

 

[lifepo4ever]

Heatshrink and dielectric grease.

agreed

 

[spinningmagnets]

LFP has made some positive comments about the Hobby-King "XT-60" connectors. The last time I ordered some parts from HK, I added a bag of XT60 pigtails. I am very impressed with these. The pins and sockets are the standard 3.5mm bullet connectors.

http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=4136

The housings are polarised so you can't plug them in backwards (of course), and although they are still small, they are just slightly larger than Deans so I have found I can get my fingertips onto them easier to pull them apart. They have a slightly stronger holding force than Deans.

The housings are enshrouded more than Deans, so there's less of a likelyhood of an accidental short by touching something that conducts. When they are together, they are somewhat "splash resistant" though not waterproof, but certainly better than Deans in that regard. I will still use Deans on occasion, but I will definitely use these as my default E-bike connector.

I believe HK rates them at 60A continuous and 95A peak. If you buy raw connectors, this style is MUCH easier to solder the wire ends to, with a confidence that the connection is very strong (I tried to UN-solder one once, and it is a suprisingly strong connection).





$3.20 for five M/F pairs, and add some 5mm heat-shrink for 12-ga wires, easily accepts 10-ga wire with 6mm heat-shrink (LFP has even used 8-ga)

http://www.hobbyking.com/hobbyking/store/uh_viewitem.asp?idproduct=9572
For total weatherproofing, perhaps get a $12 pair of Weatherpacks, they are the best. http://endless-sphere.com/forums/viewtopic.php?f=2&t=23758