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Old 08-07-2019, 17:29   #1
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Small wires - alternative to Butt connector

I always use heat-shrink butt connectors. I was replacing a v-berth fan yesterday and got stumped. The small wires connect through a small hole in the cabin top. When I pulled the old wires out, the connection between it and the boats wiring was very thin, allowing passage through a small hole.

How do you do a thin connection for low power small wires? The connection of the fan wires to the boats wiring was very small, maybe soldered or something. I would have no way to solder in that position and don't know how anyone else could either.

I had to drill a bigger hole to allow the 22-18 butt connectors to get into the roof and it worked fine this time since the hole isn't a visual problem, but what is the option for small wires? The fan uses 6 watts - 12 volt.

Any advice?
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Old 08-07-2019, 17:49   #2
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Re: Small wires - alternative to Butt connector

In aircraft I see solder sleeves used for instrument lighting. They are as easy as can be. EBay.
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Old 08-07-2019, 17:56   #3
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Re: Small wires - alternative to Butt connector

These 3M Scotchlok UR2 and UY2 connectors are good for small wires.

The connector is filled w/ a sealant for moisture resistance.

They are rated for 26-19 AWG solid conductor.
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Old 08-07-2019, 18:34   #4
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Re: Small wires - alternative to Butt connector

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In aircraft I see solder sleeves used for instrument lighting. They are as easy as can be. EBay.

Be wary. The 3M ones are very good and much of the eBay ones are pure crap (I've tested some of them and they failed utterly). There is also no way to inspect your work.
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Old 08-07-2019, 18:36   #5
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Re: Small wires - alternative to Butt connector

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These 3M Scotchlok UR2 and UY2 connectors are good for small wires.

The connector is filled w/ a sealant for moisture resistance.

They are rated for 26-19 AWG solid conductor.

But they are NOT recommend for stranded wire, only solid wire. They can damamge the strands.


If it needs to be super thin, I think everyone will recommend solder and heat shrink. The challenge is the geometry, but we have faith in you. Proper crimping takes room too.
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Old 08-07-2019, 18:58   #6
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Re: Small wires - alternative to Butt connector

https://pbase.com/mainecruising/terminating_small_wires

not on the new site?

https://marinehowto.com/marine-wire-termination/

http://www.trawlerforum.com/forums/s...ais-37679.html
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Old 08-07-2019, 19:02   #7
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Small wires - alternative to Butt connector

Quote:
Originally Posted by wingless View Post
These 3M Scotchlok UR2 and UY2 connectors are good for small wires.

The connector is filled w/ a sealant for moisture resistance.

They are rated for 26-19 AWG solid conductor.


I use these, I like them and have had good luck with them forever. They were intended I believe for telephone wires back in the day, you would see hundreds of them in a telephone junction box.
I cut the wire to my 4G Radar a coupe of years ago and used these to connect the tiny wires back together. Good luck soldering them in the location I was at.
I believe they are filled with silicone grease
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Old 08-07-2019, 19:35   #8
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Re: Small wires - alternative to Butt connector

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Originally Posted by PamlicoTraveler View Post
I had to drill a bigger hole to allow the 22-18 butt connectors to get into the roof and it worked fine this time since the hole isn't a visual problem, but what is the option for small wires? The fan uses 6 watts - 12 volt.

It's a problem of having enough free wire to splice comfortably, and room and/or a big enough hole to hide the spliced wire once connected.

Your procedure was just fine.
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Old 09-07-2019, 05:22   #9
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Re: Small wires - alternative to Butt connector

Thanks for all the great responses. I also found these self soldering connectors.

Looks like a great idea to me.
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Old 09-07-2019, 05:54   #10
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Re: Small wires - alternative to Butt connector

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Originally Posted by PamlicoTraveler View Post
Thanks for all the great responses. I also found these self soldering connectors. ...
3M had a version, out in the 1990's. They pulled them from the market.
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Old 09-07-2019, 06:09   #11
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Re: Small wires - alternative to Butt connector

I just drill the holes bigger it they need to pass. I cover the hole with some caulk or a mechanical wire fastener to hold the fan wire. You can see that of course but it doesn't catch your eye the way a hole does.
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Old 09-07-2019, 09:15   #12
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Re: Small wires - alternative to Butt connector

An alternative opinion: I don't like equipment to be spliced directly to the ship's wiring. There ought to be a disconnect so that everything can easily be removed for servicing, troubleshooting, or replacement without cutting wires. That might consist of disconnect terminals, terminal strips, or a branch-circuit fuse block.

Another heresy: When you absolutely must butt-splice and fancy connectors are weeks away by slow coach, a Western Union Splice works fine.
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Old 09-07-2019, 09:47   #13
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Re: Small wires - alternative to Butt connector

I've soldered these small, low-Amp wires and done the shrink wrap. What do you think of using liquid electrical tape as a sealant instead? I would think that this would make a waterproof seal. I do not know about the ABYC requirements, but the product descriptions (examples below) seem to indicate waterproof, high dielectric resistance, and abrasion resistance. Plus, I don't have to borrow a hair dryer to apply!

Permatex" https://www.permatex.com/products/ad...ectrical-tape/

Starbrite: Liquid Electrical Tape - LET
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Old 09-07-2019, 10:13   #14
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Re: Small wires - alternative to Butt connector

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Another heresy: When you absolutely must butt-splice and fancy connectors are weeks away by slow coach, a Western Union Splice works fine.
See page 84 of NASA-STD 8739.4
http://<br /> http://www.hq.nasa.gov...NSTD87394A.pdf
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Old 09-07-2019, 10:16   #15
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Re: Small wires - alternative to Butt connector

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What do you think of using liquid electrical tape as a sealant instead?
Relevant thread Protective film for electrical connections
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