With the proper tools, crimping is virtually foolproof. Both methods can produce reliable connections if performed correctly, but it’s far easier, faster, and safer to produce consistently good connections via the crimp method. I’ve used both methods extensively, and maintain my opinion that crimping wins over solder, and I am in the good company of automotive, aerospace, military, and medical industries. Update: The topic of soldering versus crimping is often debated, and I’ve received comments to this post arguing solder as the preferred method. This sparked my interest in the correct way to make reliable electrical connections. In my effort to create a reliable electrical connection by soldering I ended up with the exact opposite. The problem was easy to fix but it was a long and painful journey. I naturally turned my attention to the connector and quickly discovered one of the soldered connections had failed. The conductor pairs were partially held in place by the connector housing and heat shrink, but it took only a little agitation to break the flow of current. While testing a new fuel pump I bumped the connector and the pump sputtered. In my effort to create a super reliable electrical using solder I ended up with the exact opposite. I suspected the cause was fuel delivery – which ultimately proved true – but the specific issue was time consuming and difficult to root cause. All was well for a few weeks, but then I started experiencing problems with the engine cutting out in a bumpy, high-speed turn at Pacific Raceways (T10). I added an external connector so I could remove the cell for serviceability and soldered the wires to ensure a reliable connection – or so I thought. Several years ago I installed a fuel cell with internal electric fuel pump. With a little bit of knowhow and the right tools, you can create reliable connections quickly and safely. After all the time, money, and effort that goes into a race weekend, losing a race to a failed electrical connection is incredibly frustrating – and almost entirely avoidable. IntroductionĪutomotive electrical problems can be amongst the most frustrating to diagnose, with loose or faulty electrical connections being a common cause. The intended audience is enthusiasts who don’t have any formal training in the area but like or prefer to do their own wiring projects, which can range from a simple radar detector installation through full chassis and engine harness fabrication. It is not intended to be an authoritative or comprehensive guide, but rather an introduction to basic concepts, hardware, and methods that have served me well. This post details the proper method for making automotive electrical connections using the crimp method.
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