Joining into a vehicle wiring loom

[Migmac]

putting a remote locking unit into my truck. I know the wires I need to tap into, they are deep under the dash. Not enough room to get a soldering iron in to do the job. Scotch locks look the easiest option but not to keen on them, what does my one else use in tight awkward places?

 

[HughF]

Wago connectors? Crimp/shrink/solder sleeves with a heat gun?

 

[Robotstar5]

Wago connectors? Crimp/shrink/solder sleeves with a heat gun?

Sold as Helacon at VWP or proper Wago connectors cheaper from TLC, either will need enough slack cable to terminate side by side or use a loop-in connector if not enough slack.

 

[ajlelectronics]

Please, not Scotchloks. They are the mark of a true bodge artist in many people's eyes. If you don't want to solder, then use crimp connectors or Lucas bullet connectors.

 

[HughF]

Lucas bullets would be a good idea...

 

[ajlelectronics]

Lucas bullets would be a good idea...

Well I like them.

(Said Florence; hopefully).

 

[keithski122]

If you can't get a soldering iron in there you need a smaller soldering iron, if you can get pliers or crimpers in to get a connector in you can get a soldering iron in.As previously said scotchlocks are for bodgers, if you're tapping into a wire then soldering is really the only way.
I used to be thatchem approved for fitting alarms and scotchlocks were banned, everything had to be soldered/insulated and fitted so that it looked factory.

 

[wookie]

Please, not Scotchloks. They are the mark of a true bodge artist in many people's eyes.

Seconded (or thirded or wherever I'm in this queue) I've fixed no end of wiring problems over the years due to wires corroding inside the sleeve after scotchloks have been used.

Either bullets or solder, If you solder just be careful to tie the wires so they can't move as it can lead to the wire snapping since it can't flex like it used to do.

 

[Migmac]

Right, no scotch locks. Didn't like them anyway. Right next plan, make room to get soldering iron in. Will take longer but my time is free. Cheers guys

 

[Kayos]

Always worth soldering, a gas one is handy for under the dash, just watch where you put it

 

[Robotstar5]

Might be worth investing in this style of wire stripper, it can strip the insulation anywhere on a cable, do it twice about 10mm apart and remove the loose bit with a sharp knife and you've got your "tap-in" point ready to solder to.

 

[500e]

Gas irons can have nasty effect on other wires, plastic trim ect. the Exhaust port can melt flesh & other more expensive bits that have no auto-repair facility
Have 3 & they have all tried to set me on fire at one time or another.
Found this link worth a read
http://www.epemag.wimborne.co.uk/gas-soldering-iron.htm

 

[steveo3002]

id vote for pulling a few more bits of trim out until you can get to it with a soldering iron

then bare a bit of original wire without cutting it and wrap around the new bit and solder it

 

[normspanners]

If soldering was the best way to join wires manufacturers would use it, they dont because of vibration fractures, all joints are crimped to maintain flexibility.

I use a lot of glued heat shrink now, you dont need to solder, because that can cause a fracture point especially on rear hatches doors etc, with the glue type stuff all you need to do is wind the wire together properly ie put the two wires at 90degs and twist then heat shrink till the glue appears and you have a joint that is water proof, permanent and stronger than original wire but hardly any bigger dia than original.
that is how multi core wires are joined in production if one strand runs out or breaks on long runs.
I have had solder joints causing the cable to break at the solder end up inside the insulation, under vibration /movement etc.

 

[500e]

What do Thatcham say nowadays
Norm the problem with your suggestion is if you want to join a wire into an existing run you have to cut it to thread heat shrink, so you now have 3 ends to join.

 

[steveo3002]

kinda depends where it is

okay a soldered join near the door hinge thats flexing all day is going to snap , but something up under the dash that wont ever move will be fine

 

[barracuda816]

I have soldered many joints and cables working on aircraft. Until relatively recently soldering was very common and i never had an issue with fracturing (even on helicopters).

Although crimping is preferred as it is extremely durable if done right with the right tools, if don’t over tin the wire so the solder doesn’t leach too far back and use a decent 63/37 solder you wont have problems. (As long as the looms are correctly routed, not stretched bend radius is ok ect.

wagos are good and easy though.

 

[ajlelectronics]

That is the key... Don't allow the solder to wick back. Not so much of a problem if you heatshrink afterwards as a strain relief, but still better avoided.

 

[cecotto479]

This is the recommended way to do it.

 

[barracuda816]

That really messes with my OCD.