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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731

Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Joining 3 electrical cables - properly?
Hi chaps Smile

Just looking for some electrical advice please - I need to re-wire a lighting harness with 2 cables joining onto 1. Normally I would just solder them side by side but the cables are 6mm2 (2.25mm diameter) and all three together are just too much for my biggest iron to do a tidy job.

Are there any clever mechanical methods out there or is crimping my only other option. Bear in mind this connection will probably have to stand up to the elements...

Any suggestions much appreciated Bow down

Cheers
Matt Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #296678 7th Jan 2014 8:14pm
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shaggydog



Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

United Kingdom 1991 Defender 110 200 Tdi USW Arles Blue
I'd use a blowtourch and solder them that way?

As long as your quick can be done quite quickly and neetly, then just slide over some heat shrink once cool and shrink using a soldering iron. Thumbs Up
Post #296680 7th Jan 2014 8:17pm
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731

Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Cheers Smile

Hmmm - I've used a blowtorch on go-kart battery cables (50mm2) before but they were huge (also lots of burning rubber). I've played with the mini-blowtorches in the past but all the ones I've had were crap - can you suggest a make? Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #296684 7th Jan 2014 8:21pm
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6093

United Kingdom 2006 Defender 110 Td5 SW Epsom Green
A tinning iron will do it... one of those huge copper lumps that you heat up with a blowtorth, then use it to solder... they "hold" far more heat than a regular electrical iron can, and will do that size cable easily.

If it were me, i'd stagger the join. so, strip back say 2" of sheathing of the main cable, then "tin" it (load it with solder)

Get the other two cables, strip the ends (half inch or so), tin them both

Then join one side-by-side on the 2" of stripped cable, apply heat and a little more solder and the two will flow together.

Then the second piece, side-by-side but an inch or so further up

Cover well in insulating tape, then heat shrink on top of that. if it's going to be outside, maybe some dielectric grease or battery terminal grease before you cover in tape.
Post #296686 7th Jan 2014 8:32pm
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VeeTee



Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

Netherlands 
2.25 mm is not that much... A have a Weller 100 W soldering gun with different tips, that will do easily this diameter. Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
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1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
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MySite
Post #296690 7th Jan 2014 8:38pm
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731

Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Brilliant - thanks guys.

Jim - never heard of a tinning iron before (I just tin my wires before soldering) - clever solution to get lots of heat in the right place without torching everything - thanks for the detailed instructions Thumbs Up
VeeTee - my iron is also 100W but it just isn't up to the task - I know how it feels Embarassed

Should be able to do a neat job now and, once I've got it right, info to pass onto my sons (whether they like it or not) Laughing

All hail Def2 Bow down Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #296695 7th Jan 2014 8:45pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20413

United Kingdom 
Solder and heathshrink. Thumbs Up $W33T $0U7H3RN $UG4R
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Post #296719 7th Jan 2014 9:32pm
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deep down



Member Since: 02 May 2012
Location: France
Posts: 204

Wales 2007 Defender 110 Puma 2.4 DCPU Zambezi Silver
If you're using heatshrink use the glue lined type and rough the cable insulation up first with emery cloth.
This will allow the glue to bond better to the cable and make it more water proof.

The other option is self amalgamating tape, again rough the cable insulation up first. Ideally a coating of Scothkote first but as it won't be submersed that often you'll be ok.

If you can twist the cables together rather than just putting them next to each other, you'll have a better connection with less chance of a dry joint.
Post #296848 8th Jan 2014 12:26pm
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731

Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Brilliant - thanks.

I'll buy some new "gluey" heat-shrink and strip them a bit more than usual, twist them and try a tinning iron. Hopefully I'll get a good joint.

Thumbs Up to all Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #296854 8th Jan 2014 12:46pm
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Re: Joining 3 electrical cables - properly?
ZeDefender wrote:
Are there any clever mechanical methods out there or is crimping my only other option. Bear in mind this connection will probably have to stand up to the elements...


a mechanical method? these things are fantastic
Post #296871 8th Jan 2014 1:49pm
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731

Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
I saw these on fleabay but thought there might be problems with water/dirt ingress and corrosion - they look really cool though Smile Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #296889 8th Jan 2014 2:56pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20413

United Kingdom 
For good measure tightly wrap it with electrical tape too. Thumbs Up $W33T $0U7H3RN $UG4R
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Post #296909 8th Jan 2014 3:34pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5720

2006 Defender 110 Td5 USW Zermatt Silver
Re: Joining 3 electrical cables - properly?
mikeh501 wrote:
a mechanical method? these things are fantastic


I've used similar on house electrics, but would not use for this purpose personally. Can't compete with a good solder joint.

Andy
Post #296992 8th Jan 2014 6:49pm
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Laurie



Member Since: 22 Feb 2008
Location: Sussex, England
Posts: 2897

England 2005 Defender 90 Td5 XS CSW Bonatti Grey
Buy one of these....
I gave up smoking years ago but I wouldn't be without mine.

http://www.knivesandtools.co.uk/en/pt/-bla...ighter.htm 
Post #297004 8th Jan 2014 7:17pm
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tatra805



Member Since: 16 Aug 2011
Location: Dolany
Posts: 436

Slovakia 2008 Defender 110 Puma 2.4 CSW Bonatti Grey
hmm,....


I was teached that soldered connections are a no-go in anything that moves and vibrates as the solder creates a lump and a pivot point for the individual wires in a flexible cable. This results in the wires breaking at the edge of the solder after exposure to vibrations.

Confusing exists with tinned cable, where each individual wire is tinned. Tinned wire is more corrosion resistant (no black CU inside exposed wires after time) and also in the tin compressing and making a better contact area when clamped (screw connectors, crimping tools, etc)

Yes I know real life etc etc i did see a lot of soldered connections although mostly repairs and not OEM connections.

Secondly i started using the wago connectors some years ago and can't fail them. there is absolutely not one of them that gave me troubles. (have about 40pcs all over the car)

For me, I'm not going back again to crimping or soldering and am using tinned wire where available.

my 2 cents only
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Post #297026 8th Jan 2014 8:20pm
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