Cruisers Forum
 


Join CruisersForum Today

Reply
 
Thread Tools Rate Thread Display Modes
Old 25-02-2014, 12:03   #1
Registered User

Join Date: Jun 2009
Location: Annapolis, MD
Boat: Sabre 34-1
Posts: 153
Connecting REALLY TINY wires (around #26)

I am attempting to wire up a couple of NMEA 0183 devices, including a Garmin GPSMap 545. The factory wiring provided for 0183 devices is, to say the least, very tiny! The wires are about the size of telephone wire -- perhaps #24 or 26? The red heat shrink crimp terminals are rated down to #22, but they really look inappropriate.

What is considered "best practice" for terminating these small wires? Solder to a larger wire? Goober up the strands with solder to make them large enough to crimp? Strip back an inch of conductor and wrap around the unstripped wire, then crimp that? Use un-insulated crimp terminals and solder to them?

Or thinking outside the box, these gel-filled crimp terminals are rated to #26. Panbo discusses this type of connector, with sort of positive thoughts.
http://www.ebay.com/itm/25x-UR2-Gel-Filled-Telecom-Splicing-Connector-19-26AWG-CN1-3581-UR2-/360574405846#ht_1406wt_1124

And on a related note, how do you strip this stuff without cutting the strands? I'm finding the best answer appears to be using my teeth -- but that is probably not approved by ABYC or my dentist!

I want to put in a terminal strip as a "junction box" to connect to a longer run of wire. I just don't know how to connect the itsy bitsy factory crap to the terminal strip.

Thanks,

Harry
__________________

__________________
sailingharry is offline   Reply With Quote
Old 25-02-2014, 12:10   #2
Registered User
 
transmitterdan's Avatar

Join Date: Oct 2011
Boat: Valiant 42
Posts: 4,021
Re: Connecting REALLY TINY wires (around #26)

I like spring loaded terminal blocks. They make a gas tight connection to the wire. They come in many sizes. Here is some info:

http://www.phoenixcontact.com/global...2953_21678.htm

I think Digi-Key and Mouser sell in the US. They are very common in Europe and Aus as well.


Sent from my iPhone using Tapatalk
__________________

__________________
transmitterdan is online now   Reply With Quote
Old 25-02-2014, 12:17   #3
Registered User
 
Capt.Alex's Avatar

Join Date: Jan 2013
Location: Somewhere in the Bahamas
Boat: Hylas 46
Posts: 308
Re: Connecting REALLY TINY wires (around #26)

Radio Shack sells small terminal blocks. Just insert the bare wire and tighten the screw. No crimp terminals necessary. looks like this-
http://www.amazon.com/Connector-Poin.../dp/B0053WRTQ8
__________________
Capt.Alex is offline   Reply With Quote
Old 25-02-2014, 12:28   #4
Long Range Cruiser
 
MarkJ's Avatar

Cruisers Forum Supporter

Join Date: Dec 2007
Location: Australian living on "Sea Life" currently in England.
Boat: Beneteau 393 "Sea Life"
Posts: 12,828
Images: 25
Re: Connecting REALLY TINY wires (around #26)

I know the answer! But I have to make a phone call in 1 minute....
__________________
Notes on a Circumnavigation.
OurLifeAtSea.com

Somalia Pirates and our Convoy
MarkJ is offline   Reply With Quote
Old 25-02-2014, 13:16   #5
Registered User
 
El Pinguino's Avatar

Join Date: Aug 2013
Location: Punta Arenas ahorra
Boat: 39' Westerly Sealord
Posts: 3,952
Re: Connecting REALLY TINY wires (around #26)

Index Marine Index Marine | Cable Glands, Bulgin, Bulgin Buccaneer, Bulgin Connectors, Bulgin Plugs & More make high quality marine grade stuff Index Marine - Connector Strip

Penny to a pound any of the Radio Shack sort of stuff will have mild steel in it somewhere.....
El Pinguino is offline   Reply With Quote
Old 25-02-2014, 13:21   #6
Long Range Cruiser
 
MarkJ's Avatar

Cruisers Forum Supporter

Join Date: Dec 2007
Location: Australian living on "Sea Life" currently in England.
Boat: Beneteau 393 "Sea Life"
Posts: 12,828
Images: 25
Re: Connecting REALLY TINY wires (around #26)

I had this problem a year or so ago and posted here and was told by my Betters that one needs a special tool... Worth about $100 of course ... For me to join my two wires.

Probably need a stripping gun worth another hundred bucks too.

Anyway, I strip the wires with my thumb nail. Yep it works.
And then twist the 'lil buggers together. I was going to solder them but the wires are so fine that I thought they might melt. It would certainly melt the plastic.

To go into a terminal box on the power wires (same size as the 1083 wires) i piggy backed off some wires there already. In other words I just twisted them through the larger wires and shoved them in the terminal box.

As far as I can see in the chandlers there is NO system to properly join these STUPIDLY small wires.

Just do your best.

On the good side, the connections have not been a problem. Maybe the power in them is so low that a strong connection isnt all that necessary anyway.

Mark
PS all the links given so far for terminal boxes are FAR too large for these teeny-weeny wireletts. Who invented them?
__________________
Notes on a Circumnavigation.
OurLifeAtSea.com

Somalia Pirates and our Convoy
MarkJ is offline   Reply With Quote
Old 25-02-2014, 13:26   #7
Registered User

Join Date: Feb 2013
Location: S.E. Pennsylvania
Boat: Catalina 28 MK I
Posts: 64
Images: 1
Re: Connecting REALLY TINY wires (around #26)

When connecting my gps to the vhf I used the gel filled telco connectors mentioned in your original post. I think I stripped the wire with a fingernail and a pinch, may have used a knife blade to gently score the cut.
The wire is too fine for the screw terminals, not stiff enough for the spring connectors.
__________________
brazenarticle is offline   Reply With Quote
Old 25-02-2014, 13:42   #8
Moderator
 
nigel1's Avatar

Cruisers Forum Supporter

Join Date: Oct 2009
Location: Manchester, UK
Boat: Beneteau 473
Posts: 5,184
Re: Connecting REALLY TINY wires (around #26)

I used the ones you originally linked to, cheap as chips, water proof, and easy to make, no stripping and no special tools needed.
Raymarine recommended them for joining their signal wires.
__________________
Nigel
Beneteau 473
Manchester, UK
nigel1 is offline   Reply With Quote
Old 25-02-2014, 13:46   #9
Registered User
 
JK n Smitty's Avatar

Join Date: Aug 2012
Location: Hingham, MA
Boat: Catalina 310
Posts: 637
Re: Connecting REALLY TINY wires (around #26)

I am a MaineSail groupie so I will suggest you check out the Compass Marine article. As usual, he provides a complete, easily understood article.
__________________
http://svsmitty.wordpress.com/
JK n Smitty is offline   Reply With Quote
Old 25-02-2014, 13:50   #10
Registered User
 
Reefmagnet's Avatar

Join Date: May 2008
Location: puɐןsuǝǝnb 'ʎɐʞɔɐɯ
Boat: Nantucket Island 33
Posts: 2,735
Re: Connecting REALLY TINY wires (around #26)

The telco gel connectors work ok. I'm going to use them to join a connector to suit my upgraded wind transducer to the old cable at the top of the mast due to the inconvenience of trying to solder up there. Usually I would just strip, twist and solder and then slip some heat shrink over the top which works fine for new wires (not so good for old, corroded ones).

On a side note, I've been using this style of wire stripper for near on the last 25 years. In fact I still use the original pair I brought way back then...



These will strip fine wire very precisely and aren't that pricey to buy.
__________________
Reefmagnet is offline   Reply With Quote
Old 25-02-2014, 17:35   #11
Certifiable Refitter/Senior Wannbe
 
Wotname's Avatar

Cruisers Forum Supporter

Join Date: Jan 2008
Location: South of 43 S, Australia
Boat: Van DeStat Super Dogger 31'
Posts: 7,331
Re: Connecting REALLY TINY wires (around #26)

Quote:
Originally Posted by sailingharry View Post
.........
[SIZE=3][FONT=Calibri]What is considered "best practice" for terminating these small wires? .........
Crimp or solder, your choice. Of course the trick with crimping them is to find crimps small enough (and they do exist) but then you also have to have the "right" crimping tool so for a one off project, solder is usually the easiest way to go. Small iron, normal 60/40 thin solder (something around say 30 gauge) and some heat shrink tubing. Soldering such small wires is an everyday occurrence in a radio / electronics workshop

Quote:
Originally Posted by MarkJ View Post
.........
Anyway, I strip the wires with my thumb nail. Yep it works.
And then twist the 'lil buggers together. I was going to solder them but the wires are so fine that I thought they might melt. It would certainly melt the plastic...........
Yep, stripping is easy and so is the twisting
Solder won't melt the wires, they are still copper and your iron will never get hot enough to melt copper
Too much heat will melt too much plastic (insulation) but as you only need a tiny amount of heat to solder these wires, you will be OK providing the tip of the iron is small, the solder thin and you are quick with the soldering technique.

It is just a technique, one easily learned but the only trouble I have is seeing the little buggers these days. The magnifying glasses certainly help
__________________
All men dream: but not equally. Those who dream by night in the dusty recesses of their minds wake in the day to find it was vanity: but the dreamers of the day are dangereous men, for they may act their dreams with open eyes, to make it possible. T.E. Lawrence
Wotname is offline   Reply With Quote
Old 25-02-2014, 18:06   #12
Nearly an old salt
 
goboatingnow's Avatar

Cruisers Forum Supporter

Join Date: Jun 2009
Posts: 13,649
Images: 3
Re: Connecting REALLY TINY wires (around #26)

Most professional is uninsulated crimps and no solder. Gel filled scotch connectors are good too.

Alternatively just solder then together and heat shrink

Dave
__________________
Check out my new blog on smart boat technology, networking and gadgets for the connected sailor! - http://smartboats.tumblr.com
goboatingnow is offline   Reply With Quote
Old 25-02-2014, 18:17   #13
Registered User
 
ShaunJ's Avatar

Join Date: Oct 2010
Location: Md, USA
Posts: 430
Re: Connecting REALLY TINY wires (around #26)

+1 on the telco connectors,we called these scotch locks when I used them as a cable splicer for the phone company. A few of the nice things about these are that you don't need much wire to do a repair, any pliers will crimp them, you can join different size conductors and up to 3 wires can be connected.
__________________
ShaunJ
I get knocked down...But get up again...
You're never going to keep me down....


ShaunJ is offline   Reply With Quote
Old 25-02-2014, 18:17   #14
Registered User

Join Date: Mar 2013
Location: Annapolis, MD
Boat: Sail any boats from 28 to 60 ft
Posts: 530
Re: Connecting REALLY TINY wires (around #26)

Quote:
Originally Posted by sailingharry View Post
Connecting REALLY TINY wires (around #26)
Harry
Think outside the box, I would just use RJ11 or RJ45 to connect them? You need to find the appropriate female side of RJ11 or 45.
__________________
rockDAWG is offline   Reply With Quote
Old 25-02-2014, 18:22   #15
Registered User

Join Date: Jul 2008
Posts: 81
Re: Connecting REALLY TINY wires (around #26)

Hello Harry:
when I have to connect small wires, I first strip both, then put them side by side instead of end to end. Next I either tie them or wire tie them together on the insulated part of the wires. I prefer to solder, and then heat shrink.
Good luck however you do it.
__________________

__________________
decktapper is offline   Reply With Quote
Reply

Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -7. The time now is 06:46.


Google+
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Social Knowledge Networks
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2017, vBulletin Solutions, Inc.

ShowCase vBulletin Plugins by Drive Thru Online, Inc.