My son and I have been going bonkers on wiring, trying all different connectors, heat shrink, etc. I think we finally bottomed out on a few great options to have a solid, nearly indestructible solution. This is nothing new for the veterans out there, but this has/is the biggest wiring project I’ve ever experienced. So I thought I’d share with the crew.
Our goal is to solder where permanent, and have disconnect behind the dash components. Just to add, while the RF harness has the Nylon insulated connectors but we’re about 70% failure rate on the ones we’ve crimped, so we switched. The RF team must use a different tool for their connections, probably some type of specialized electrical crimp tool
Here’s a quick reference to all the tools, products that we’ve been using. They’ve been critical for us, and hopefully helpful for you. We do get a small portion of funding from these links, so please use them to feed the need for more tools! <3
Solder setup – we used this because of the programmability options
It heats up VERY quickly and is fully portable no matter where you are in the garage, all for about $140
TS100 Digital OLED Programmable Soldering Iron Station $68
DeWalt 18V/20V Lithium Ion Battery,TS100 Soldering Iron, USB Charger $20
Kester Pocket Pack Solder 60/40 0.031 $17
Soldering Ion Tip Cleaning Wire and Holder Coiled Brass Sponge Tip Cleaner $14
and just recently got Helping Hands Soldering Station $22
lastly, get a Wirefy Heat Shrink Tubing Kit – 3:1 Ratio Adhesive Lined, Marine Grade Shrink Wrap, about $14, but you’ll have a watertight seal!
I did play with these Solder Seal Wire Connectors ~$22 which includes it’s own heat shrink and solder in the joint
they do work really well when you get used to the usage, but you do need to be careful using a heat gun in closed spaces – I did some carpet melting by accident 🙂 Also, in the above pic you can see one section of the Head and Tail Light Wiring Kit, Quick Disconnect from Breeze Automotive, which brings me to the next section – connectors!
Connectors:
There are so many types of connectors in a 12v setup it can get overwhelming, primarily based on preference, but some of it is functional depending on your amperage requirements.
Here’s a good site to see what size wire is sustainable at what amperage level: https://www.cerrowire.com/products/resources/tables-calculators/ampacity-charts/
We used 3 types of connectors: Exterior, Interior, and Copper Lug
Exterior (e.g. could get wet) connectors – tried and true Weather pack connectors are excellent, as well as the pigtail setup as shown above in the Breeze setup.
2 Pin Connector for 20-14 AWG Wire Connectors 2.5mm Series Waterproof Connector Electrical Sockets $10
you can use the IWISS Ratcheting Crimping Tool Set 8 PCS – Quick Exchange Jaw for Heat Shrink, Non-Insulated, Open Barrel, Insulated and Non-Insulated Ferrules AWG 20-2 $45
Interior – spade and/or ring connectors, these have advanced quite a bit over time
pro tip especially for thinner wires:
- Add some solder to the wires, this is called tinning. This process helps to give more surface for a better mechanical crimp
- Slip the heat shrink glue infused connector, if tinned, it should feel like a solid wire fitting into the connector perfectly
- Lastly, using a heat gun, you shrink the connector, and hold it for a few more moments. The glue melts and covers the joint
You can see a little bulb of the glue at the base of the connector – these connections are now solid, the only way to separate is to cut or destroy the connector… perfect!
The Wirefy brand has not failed me (pics above) – highly suggested (or a variant like them)
Wirefy Spade Connector Kit – Male and Female Spade Wire Connectors Kit – Quick Disconnect Electrical Terminal Connectors – 22-10 Gauge $28 and comes with a nice case!
Wirefy Heat Shrink Wire Connectors Kit – Marine Grade Electrical Connectors – Automotive Butt Connectors – Insulated Ring, Spade, Fork, Hook Crimp Terminals – 22-10 Gauge $55
2.8mm 2 3 4 6 9 Pin Plug Housing Pin Header Crimp Electrical Wire Terminals Connector – $17 awesome setup for making quick disconnect behind the dash or other areas that may need dis-connectability
you can use the same IWISS Ratcheting Crimping Tool for these connectors as well!
Copper Lug/Large Gauge Connectors – anything larger than 10 gauge, think engine bay or high-power transfer
Copper Wire Terminal Connectors, AWG 2 4 6 8 10 12 Ring Lug Kit with Heat Shrink $15
for this setup you need a Hydraulic Crimping Tool and Cable Cutter Hydraulic Cable Lug Crimper 8 US TON 12 AWG to 00 (2/0) Electrical Terminal Cable Wire Tool Kit with 9 Die $49
Lastly, we are labelling almost every wire we touch.
This is probably one of my favorite “tools” in the build, the RHINO 5200 Label Printer Kit is pricey ~$167, but it does a great job! Now our own wiring looks as good as the RF kit!
Hopefully this is helpful – would love feedback from the forum – I’m a very novice electrical guy, and learning but wanted to share what is working well!
