Butt connection Vs. Solder on automotive wire harness: To crimp or to solder? That’s a question.
Michael Niu
Business Development Manager| Focus on Custom Cable Solutions| One-stop Services
Butt connection Vs. Solder on automotive wire harness: There are several ways to connect wires in automotive wire harnesses. But the main problem is where you should go for heat shrinking, soldering, butt connectors?
People often believe butt connectors are better for power and ground wires than soldering and heat shrinking, as soldering makes the wires stiff and prone to breakage during vibrations.
So, which is better for vehicles – butt connector vs. solder on automotive wire harness? And for a third option, can heat shrink be used over the butt connectors?
Let’s find out in this article.
Table of Contents
Butt connector vs. solder on automotive wire harness: The basics
The primary reason for the problems in the electrical connection is faulty connections in wires and cables.
?Most applications use crimp terminals as they are reliable and efficient. However, it can develop corrosion over time, leading to issues in the connection.
?Another reliable method to repair electronic devices is soldering.
Butt connector:
In the butt connection, you use a splice connector, which is a simple cylindrical connector having crimps at both ends.?
This is the most common and helpful connector in electrical applications. It’s a crimp connector that helps terminate wires safely and connect them.?
Solder on automotive wire harness:
Soldering is a traditional way of terminating wires. You use a molten metal, solder, to form a reliable and strong connection between wires, cables, or any other electrical components. The metal solder can be anything of silver, brass, or tin.?
Butt connectors vs. Solder on automotive wire harness: The pros and The cons
Though both butt connector and soldering help connect wires, the butt splice connector is better than soldering. Let’s find out how.
Butt connection Vs. Solder on automotive wire harness: Applications
In the aerospace and automotive industries, you need reliable and robust connections.?
The crimped wires create a cold weld, whose pressure leads to the formation of metal and its oxide layers at the micro level.?
Thus, butt splice connectors are the most reliable and efficient wire connection method.
On the contrary, you can use soldering to connect wires and terminals in low-current and delicate applications like circuit boards in electronics.?
However, if your car is down on the road, you may prefer soldering the wires to crimping since they seem to be the proper method of handling.
Is it helpful to heat-shrink butt connectors?
Sometimes, engineers also use heat shrink to seal the butt connector ends, which results in the contraction at the end, locking the wires and butt splice connectors and making them weather resistant.
Heat shrinks are a unique insulation that shrinks on applying heat, which usually has an adhesive.?
?If you see an opaque plastic insulator, don’t mistake it for a heat shrink connector, as it will melt on applying heat.
These connectors are preferable for all wiring applications in trucks, cars, boats, trailers, campers, and other vehicles.?
You can use these butt splice connectors with heat shrink for repairing wire damages caused due to rodents, corrosion, and other reasons.?
Whether for temporary or permanent repairs, the connection is reliable and long-lasting.?
Another good thing about heat shrink insulation is that they are color-coded for the intended wire gauges.
Tools required for heat-shrink connectors:
You need the following tools, along with the heat-shrink connectors, to make a firm connection.
Crimper:
There are several types of crimping tools and crimp-on wire connectors.?
Thus, it is essential to choose a suitable crimper; otherwise, it can deform the metal, damage the insulation, make a wrong crimp connection, or lead to all three together.
Wire stripper:
Before crimping, you must strip off the wire insulation for about 3.16 of an inch. An automatic wire stripper makes the work easier and faster but is costly.??
If you don’t want to invest in it, a simple, inexpensive wire stripper will also do.
Heat gun:
You want a source for flames to provide heat to the insulation but don’t just bring a cigarette lighter or anything like that. Heat guns provide heat in a controlled manner and are worth an investment.
The right way of using heat-shrink connectors:
Conclusion:
So, weigh the pros and cons according to the applications when deciding on the connection.?
Always remember that your priority should be the quality of the connection.?
Cloom is here to clarify your doubts regarding crimping or soldering. We have years of experience implementing different custom wire harnesses and cable assembly types.