Sometimes in a car or in other jobs, you might have to join two wires together. There are different ways to do that and soldering is a common way of joining two wires. You get the two wires together and put some solder to connect them. However, you might not have access to solder at all times. So in this article we will discuss how to connect two wires without soldering.
One way can be by using ‘crimp connectors’. Another way is by using the ‘twist method’. This article will mainly focus on connecting wires using these two methods.
Preparing wires for a good connection?
Let us first look at how you should prepare the wires for a good connection. First remove a part of the covering layer (insulation covering) of both the wires to be connected. For that you will need a wire stripper which you can get at a local hardware store.
Get one where you have the various gauges for stripping and then you also have the part that crimps the connectors. It is easy to use and will make the process smooth and easy for you. Use the wire stripper and the gauge to strip the wire.
If you plan twisting the naked part, remove the layer a little more (a little over an inch) than you’d do when you using a crimp connector. Then you need to wound each of these wires such that they are nice, tight and firm together.
How to connect two wires without soldering
After you have the two wires ready for joining, bring in the base of the naked portion of the two parts together.
In case of crimping, put the butt connector in between the edges of the crimper. Then put the first wire in the butt connector and give a little squeeze. Then get the other piece of wire and put the naked portion into the other end of the butt connector. Again give a little squeeze. That’s it. You will have a very good means of crimp butt connector to connect two wires together.
In the case of twisting, start twisting them really tight together all the way to the top. Make sure that you make the twisting really tight. After you are done twisting the two naked wires portion together to the top, bend the twisted portion into half. Then lay the twisted portion over either side of the joined wires. So you have completed the skeletal framework and now you have to seal it.
How to cover the bare wires?
In the case of twisting, after you have the wires twisted, it is time to seal up the twisted portion since it is bare.
To join them together you need to use some shrink tubing (or you can also use some electric tape also). When using shrink tubing you should make sure that the tubing is a little larger than the wire itself.
You need it put in the tubing. Push and spin the tubing delicately till it is placed on the middle of the jointed portion. Then with the heat gun you must shrink the tubing. After you have shrunk the tubing, you are done. You are ready with your connection.
This method is great if you can’t access the area with a soldering gun or a crimp connector. Also this method of joining keeps the wire flexible. Unlike the solder it doesn’t get brittle and hard with time, so, it will continue to bend.
Also you are not compromising with the quality of connection as our experiments show that resulting joint is really strong. This ensures that the connection won’t come off unless you exert some intense pressure on the wire.
If shrink tubing is not available, then you can go for electrical tape for wrapping up the bare wire portion. Making sure the taping it tight, multiple layered and water proof.
However, taping is not as efficient as shrink tubing. Nevertheless, it should do the job. But it isn’t a long term solution.
If high current is passing through the wire connection, over time (probably over a couple of summers) the adhesive on the tape might start wearing off.
This will cause a short circuit if other wires come in contact with the inside of the concerned wire. Also the adhesive will work itself into the individual strands of wire inside and this might cause the connection to fail.
So although soldering is most popular to connect two wires, there are other means as well. Other means include crimping and twisting. Crimping uses connecting two wires using a connector. Usually butt connectors are convenient to use and so such connectors are generally suggested.
Twisting involves twisting the naked part of the two pieces of wires tight and strong. And then bending the naked twisted part in two halves and placing it flat on one of the two sides of the wire. It is followed by covering up the naked twisted part with a covering.
You can either use a shrink tube or electrical tape for the covering. Shrink tubing is advised over tape as the former provides with a stronger joint/connection. Tapes have certain disadvantages. So it is advised that tapes should only be used for wire connection during urgent short term requirements.
It is suggested that wire connections which are made using tapes for what so ever reasons, should be replaced ASAP. You can either use a shrink tube or you can also choose to crimp the two wires using a wire stripper, crimper and a butt connector.
Thus, we have very good alternatives which can be used instead of soldering when it comes to connecting wires. Also soldering has certain flaws as such the solder leaves behind and hard portion of the wire and the solder gets brittle over time. With the above mentioned tactics now wire connection won’t be much of a headache as you might have initially thought it to be.