beaufortnc wrote:
Hi,

In my quest for the "perfect" marine electrical connection, I've
heard
and read a variety of opinions.

In general, most sources agree on the majority of subjects (tinned
wire/connectors, correct sizing, etc...)

However, when it comes to the subject of whether to solder
connections
or not, it seems that there is some disagreement.

Are high quality mechanical connections, made with the proper tool,
and
protected with adhesive heat shrink enough?

Some think that it isn't.

Any thoughts?

Thanks,

Mike.

Mike, if done properly, with the right equipment, both soldered and
crimped connections work very well. You would be hard pressed to show
proof of one being better than the other. Manufacturers prefer crimped
connections because they cost much less than soldered connections, and
they tend to be more consistant, from part to part. Their's also no
flux residue to clean from a crimped contact.

The real problem with crimped connections is that for them to perform
as designed you need the proper crimping tool and die set from the
crimp contact manufacturer. This will produce a "gass tight seal" in
the area of the crimp. If you do not have the proper die set, and tool
(the right tool and die can cost a few hundred dollars), you may over
crimp (start breaking the strands) which can result in the contact
eventually seperating from the wire. If you under crimp the contact you
will not end up with a gass tight seal, the end result of which will be
increased resistance at the point of the crimp due to corrosion (it may
take a long time for this to happen, but it will). I have never seen
anyone outside of a manufacturer that had the proper crimping tool,
people think they have the right tool but they don't, their just not
common.

Because of the reasons above, your best bet, without spending lots of
money on special crimping tools, a soldered joint is probably the most
reliable connection method for you. Stick with tinned wires and tinned
contacts, solder with 63/37 rosen based solder, don't apply too much
solder (it can wick up under the insulation), don't melt the
insulation, and clean the flux residue off with a spray cleaned. If you
do cover the ternination with heat shrink it's also a good idea to
cover the final termination with a product like Liquid Tape. A
connectoin made in this manner should last for a long time if not
exposed to too much moisture.

I hope this helped to answer your qusetion.

John