How to do a Basic Wire Splice

skykeith said

Those of us whose work is approved by the FAA, American boat and yacht council, etc. have to use butt connectors, because solder splices are not approved. That may be the mark of an amateur, but there's not a single OEM vehicle manufacturer (including riding lawn mowers) that solder splice wiring.

Click to expand...

Interesting. A former co-worker who worked as a railroad design engineer said they considered crimps equal to solder as regards corrosion. I have seen that claim from terminal manufacturers too. If you get a very tight crimp, it can stay oxygen-free at the interface, so no copper oxide forms. However, soldered joints are probably good for corrosion resistance too since traces on circuit boards are "tinned" with solder to keep the copper from turning green. In humid environments, even better to spray a polymer "conformal mapping" on the circuit board. Adhesive heat shrink is likely similar. If you use RTV, don't use the normal type that smells like vinegar. The acetic acid can cause corrosion.

Not sure why soldered splices aren't allowed some places. Perhaps it has to do with more variability in quality than a butt crimp and more difficult to inspect. If the butt crimp also grabs the wire insulation, that adds to durability. They sure take more space and look clumsy too.