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Dumbest epiphany of all time this morning.

I crimp most stuff, stuff the crimps w/ DG, and heatshrink...

I'm not gonna pretend my truck isn't full of electrical tape, too... :whistle:
 
So how do I know what tools are "good" and which aren't? Craftsman's got a nice looking multimeter for about $50. How do I know on strippers, crimpers, etc.?

Colby, I'm an electrician, alot of what I do doesn't directly transfer over to automotive work, but the tools are the same. A $50 craftsman multimeter will be fine for the work you'll be doing. I actually use a little $20 one from napa on my truck, but if you do electrical all the time, then you can't beat Fluke, but that is $$$. Alot of stripper/crimpers are all in one, but I prefer seperate tools, they are less bulky. For strippers, I use these: http://www.sears.com/shc/s/p_10153_12605_00973573000P?prdNo=7&blockNo=7&blockType=G7. Klein, Greenlee, and Craftsman all sell the same pair, just with different color handles and names. As for crimpers, I use these: http://www.homedepot.com/Electrical...splay?langId=-1&storeId=10051&catalogId=10053

As for materials, locally the JT&T brand stuff that Napa sells seems pretty good, and Summit sells some pretty nice assortments of connectors, splices, and heat shrink off the shelf.
 
Colby, I'm an electrician, alot of what I do doesn't directly transfer over to automotive work, but the tools are the same. A $50 craftsman multimeter will be fine for the work you'll be doing. I actually use a little $20 one from napa on my truck, but if you do electrical all the time, then you can't beat Fluke, but that is $$$. Alot of stripper/crimpers are all in one, but I prefer seperate tools, they are less bulky. For strippers, I use these: http://www.sears.com/shc/s/p_10153_12605_00973573000P?prdNo=7&blockNo=7&blockType=G7. Klein, Greenlee, and Craftsman all sell the same pair, just with different color handles and names. As for crimpers, I use these: http://www.homedepot.com/Electrical...splay?langId=-1&storeId=10051&catalogId=10053

As for materials, locally the JT&T brand stuff that Napa sells seems pretty good, and Summit sells some pretty nice assortments of connectors, splices, and heat shrink off the shelf.


Cool! Thanks. :) I've been meaning to ask you how you got into it. Perhaps a PM conversation will ensue. :D I'm considering the possibility of pursuing that kind of work in addition to, or after, my MFA degree.
 
As far as multimeters go. I've had bad luck with craftsman ones. I spent $110 on one and it took a poop just after the 1 year warranty.
I bought a $20 harbor freight one. It's been running strong for 3+ years of abuse and I mean abuse. It also works way better than that craftsman one did over all.
http://www.harborfreight.com/ac-dc-digital-multimeter-37772.html
I've been eyeing this one though because it has an inductive pick-up to show RPM and "if" you have contact points or need/understand dwell I guess that would come in handy.
http://www.harborfreight.com/lcd-automotive-multimeter-with-tachometer-kit-95670.html

Regardless, make sure that which ever kind you buy, it has a full range of features for DC not just AC. DC is the line with dots under it.

I've got a pair of these and love them. They ratchet and will hold tight to what it is you're crimping. Making it easier in tight cramped areas. They also double crimp.
http://www.harborfreight.com/ratcheting-crimping-tool-97420.html
And then these, the're much like ones posted before but they hold one side of the wire and stip off the other side. No yanking against old fragile wires/connectors.
http://www.harborfreight.com/heavy-duty-self-adjusting-wire-stripper-36810.html

I know a lot of guys don't like HF but I've used much more expensive brands of the same basic tools and for the money you'll never notice the difference.
 
Well, I do stuff like this for a living, and been doing it for many many years.
Lets consider the soldering part first.
I am very good at soldering.
I have to be. I have had to save multilevel boards worth thousands.

I have soldered with soldering stations that cost several hundred dollars, and with a nail heated with a torch.

The station was easier.

I have run into a lot of misconceptions about soldering irons. Back when solid state stuff first started coming out, low wattage irons were what you absolutely had to have to keep from burning the small parts up.
As a result, lots of parts got burned up with low wattage soldering irons.

As it turned out, the trick was not to put a small amount of heat and capacity onto the part, the correct way was to put a lot of heat and capacity onto the part to get the joint soldered fast before the heat had time to spread.

Which is why the Weller system is the best. And what makes it so good for electronic stuff, makes it ideal for what you are doing.

I have a couple of this station.
http://www.testequipmentdepot.com/weller/solder/wtcpt.htm

Its great for me, but you might be better off served with this one.
http://www.testequipmentdepot.com/weller/popups/tcp12p.htm

I have one of them also, and it works very well.

The secret to their success is that they have a large heat source combined with a thermostat.
The low wattage irons never get over a certain temp due to the fact that the heating element can only get it so hot before it starts radiating as much heat out as it can produce.
But, when you touch the tip to a heavy piece of copper, it sucks the heat out faster than the element can replace it, and you get a bad solder joint.
If you put in a big element, it gets the tip too hot and burns up the solder.

Weller has a big element that is cycled by a magnet in the tip. When it reaches the set temp, the magnet loses its strength and a spring breaks the contacts turning off the element.
When it cools, it turns back on.
When you touch the tip to some heavy copper, it kicks the big element back on and maintains the heat.

A good iron makes all the difference in the world.

For general use under the hood soldering the heavier wires, also consider this gun.
http://www.testequipmentdepot.com/weller/solderandheatguns/d650.htm

Its the upgraded version of the old Weller 550. Its able to pump lots of heat into a heavy joint.
And would probably do about 85% of everything you needed done on a Blazer.

Next is the solder.

I use Sav-a-bit Mulicore exclusively. Unfortunately you cannot buy it any more. I bought up the last a big catalog company had several years ago, and I should have a lifetime supply.
The flux in the solder is critical. It comes in different amounts of reactivity. Too little, and it will not clean the joint well enough for the solder to bond.
Too much, and it will corrode afterwards.

Here is a long thread about soldering and fluxes.
coloradok5.com/forums/showthread.php?t=287947

Just in case you did not know, NEVER use acid core solder. If you accidentally do, cut out at least 4 to 6 inches of the wire past the joint, or that much past the green crud if you found it late, and throw away the soldering iron tip you used.

Also, you almost must use 60/40 lead/tin solder. Never 50/50. That is for soldering radiators and copper pipes.
Plus, you need to start looking for real lead solder. Its getting harder and harder to find as the nanny state bans it.
Its still the best for what you want to do.
If you have to use the new government approved lead free solder, it will work, but its an unnecessary hindrance.

Now, a quick mention of crimp connectors.
Properly done a crimp connector is as good as, or even superior to, a soldered connection.
I know, I had a hard time believing it myself. A proper crimp, will actually displace the surface film of the wire and the crimp and make an airtight bond.
I have seen the data, and I'm convinced.
But, I still solder most of my connections.
Mainly because you need expensive, controlled force crimpers, and high quality connectors to make it work.
A good setup will not only crimp the connector to the wire, but there is a second crimp that clamps down on the insulation to provide strain relief and mechanical strength.

In high vibration areas like boats, they do not recommend soldered joints. Because the solder soaks into the wire, and makes it stiff and hard.
Then, where it stops, the wire is suddenly flexible again and that creates a stress riser that can cause the wire to break at that point.

As far as heat shrink is concerned, except for places in the engine compartment real close to heat, use the adhesive lined heat shrink.
It has some hot melt glue inside the tube. It melts slightly before the tube starts to shrink. Then, when it shrinks, it gets squeezed into all the parts of the joint and out the ends.
Then it hardens but stays a little flexible.
This makes the joint both water and air tight. Stopping corrosion in its tracks.

They also sell crimp fittings with adhesive lined heat shrink insulation. Well worth the cost.
You crimp the joint, then heat it and its sealed. Saves a step.

They also sell adhesive lined, heat shrink insulated, solder inside, butt splices.
You crimp the splice, heat it, and the solder melts inside and solders the joint while the heat-shrink seals it.
Expensive and hard to find, but neat.

I may post some more ideas later, and I will try to find some links to those types of connectors and heat shrink.
 
^^^^^^^^


rampage no speaky with forked tongue!

(I'm an Aircraft electrician, to validate that statement.)
 
I SUCK at soldering. That being said, i crimp everything, and if done well for most stuff, it does the trick. If its going to be in a moist environment, I fill the crimp connector with diaelectric grease.

Soldering isn't that hard. It all has to do with everything being properly tinned - covered in a thin layer of solder. First the soldering iron - if it looks pitted and nasty then try cleaning it off with a clean wire brush or you may need to take a file to it and go down to the bare copper tip and create a new tip. Next have a wet sponge and some flux core solder handy. When the iron is good and hot touch the solder to the iron and coat it all the way around, then wipe the excess solder off using the wet sponge. If you see any bare spots on the tip try re-tinning it.
When you solder you want to tin the pieces to be joined first before you actually make the connection. To tin a wire or crimp connector touch the iron to one side of the wire for a second or two to preheat it and then touch the solder to the opposite side. Let the heat draw the solder to the iron. After both pieces are tinned connect them to each other and touch them with the iron, there should be enough solder on the tinned parts that you shouldn't have to apply any. This is a case where less is more. Hold the parts together until the solder solidifies - just a few seconds. Clean off any burnt flux with a wire brush or a Q-tip soaked with rubbing alcohol to prevent corrosion. If at any time the is a blob of solder on the end of the iron wipe it off with the wet sponge.
 
They also sell crimp fittings with adhesive lined heat shrink insulation. Well worth the cost.
You crimp the joint, then heat it and its sealed. Saves a step.

They also sell adhesive lined, heat shrink insulated, solder inside, butt splices.
You crimp the splice, heat it, and the solder melts inside and solders the joint while the heat-shrink seals it.
Expensive and hard to find, but neat.


They sell those types at NAPA around here. I love em. I use the crimp and seal connectors on fire apparatus pretty regularly. You can buy em in packs of 5 or so or you can order them in bulk.
 
What he said is true, except do not sand or grind the tips of either of the two Weller thermostatically controlled irons.
They are not copper, but have a plating on them, and it will ruin them to be ground or sanded.
The big gun tip is solid copper, and the irons with no control and the screw in tips have copper tips and can benefit from a good cleaning.

My method, is to let the iron cool, sand down to clean copper, and then wrap a single layer of good quality rosin core solder around the tip.

Plug the iron in, and when the smoke clears, its almost always well tinned.
 
They sell those types at NAPA around here. I love em. I use the crimp and seal connectors on fire apparatus pretty regularly. You can buy em in packs of 5 or so or you can order them in bulk.


That waytek link also sells ring terminals with built in solder and the adhesive heat shrink insulation.
You crimp them, and they solder themselves when you heat them.

http://order.waytekwire.com/product...hrinkable Terminals/Terminals And Connectors/

Price seems high though. I suspect you can find them cheaper elsewhere.
 
I second these crimpers...I have used them for years and years and they are great (as is anything Klein).

http://www.homedepot.com/Electrical...splay?langId=-1&storeId=10051&catalogId=10053

I like the "automatic" strippers as opposed to the ones that you have to manually cut the insulation off, especially when you're working in close quarters (like under a dash) and can only use one hand easily. I have had great ones and I have had crappy ones, and these are the ones I have been using for the last year or so. Love them and they are cheap.

http://www.homedepot.com/h_d1/N-5yc...splay?langId=-1&storeId=10051&catalogId=10053

Drop $50 (total) on good strippers and cutters/crimpers and you'll thank yourself every time you use them. Toss in a good meter and you're well on your way. Also worth mentioning, several sets of leads with your meter will come in very handy as well. I bought the Craftsman pack of I think 3 different sets because they fit a Fluke but are a lot cheaper. The main thing that will come in really handy is being able to clamp a ground lead while you probe with the other as opposed to having to use one hand just to make sure you are always getting a good ground with your meter.
 
They also sell adhesive lined, heat shrink insulated, solder inside, butt splices.
You crimp the splice, heat it, and the solder melts inside and solders the joint while the heat-shrink seals it.
Expensive and hard to find, but neat

Many many moons ago I had a sterio installed by pros at a sterio shop and these are what they used. I though "WOW that is just awesome!" I tried to find them and didnt have much luck. When I did finally find them it was a package of 3! conectors for like $8 :eek1: I kinda gave up on that idea but this was a long time ago. I would love to find these in bulk for a lot less than $2.60 each!

I did at one time find bare metal butt conectors that you crimp on then solder the ends of the wire though a hole in 1 side then heat shrink over the conection. These where handy when you have room but just didnt work out in cramped areas.

Colby, My advice that I have learned, and has helped me is always leave yourself some slack on wire jobs that may have to come out later such as car sterio installs. Maybe its just me but I used to try to minimize the wire and it just made things difficult at later times. I had to teach my self to give an extra 6" or so more than what my brain says is enough. Also taking the time to route wires well has been hard for me to make myself do. Im an impatcient person and find if I let myself rush a job I always end up having to fix it or tidy it up later then I can only be mad at myself LOL.

As for myself I try to get the adhesive heat shrink crimp conectors without the solder as often as I can. They seam to be the best cost/quality for me anyway. All the above recomended tools I would agree with and I will add if you go the heat shrink route a quality butane mini torch makes quick work of shrinking. I will warn for people like myself, sometimes in direct sunlight you cannot see that little flame but its still hot as hell.

My last advice is GOOD CLEAN GROUND CONECTIONS! I have fought with electrical stuff for hours just to finally find out its a bad ground. (usually due to letting myself rush things.)
 
electric-shock1.png
 
What he said is true, except do not sand or grind the tips of either of the two Weller thermostatically controlled irons.
They are not copper, but have a plating on them, and it will ruin them to be ground or sanded.
The big gun tip is solid copper, and the irons with no control and the screw in tips have copper tips and can benefit from a good cleaning.

My method, is to let the iron cool, sand down to clean copper, and then wrap a single layer of good quality rosin core solder around the tip.

Plug the iron in, and when the smoke clears, its almost always well tinned.


I usually do a spinning wire wheel. Then dip in flux a few times, then wrap in resin core.

Also make sure you leave solder on the tip at all times so it eats the solder not the tip :)
 
I have a couple of this station.
http://www.testequipmentdepot.com/weller/solder/wtcpt.htm
Its great for me, but you might be better off served with this one.
http://www.testequipmentdepot.com/we...ups/tcp12p.htm

For general use under the hood soldering the heavier wires, also consider this gun.
http://www.testequipmentdepot.com/weller/solderandheatguns/d650.htm

Its the upgraded version of the old Weller 550. Its able to pump lots of heat into a heavy joint.
And would probably do about 85% of everything you needed done on a Blazer.

I have the digital version of that first station. Quick question though. What do you use when you're soldering in a somewhat confined space and you can't bring your station but you're working on wires too small for that gun. That field iron you posted seems cool but seems like it runs straight off the battery and I'm not sure if it's good enough to make good joints. I'm thinking something run off of an extension cord or a power inverter off the rig.
 
I have the digital version of that first station. Quick question though. What do you use when you're soldering in a somewhat confined space and you can't bring your station but you're working on wires too small for that gun. That field iron you posted seems cool but seems like it runs straight off the battery and I'm not sure if it's good enough to make good joints. I'm thinking something run off of an extension cord or a power inverter off the rig.

Drk, gonna answer you first. That field iron is a Weller. Its basically the same iron as the station without the station.

Don't be fooled into thinking its like the other irons. It has the same oversized heater and thermostat that the station does.

I let my idiot cousin use it one time while I was standing there doing something else. He did like he does with his regular irons. He hooked it up, and then reached out and pinched the tip between thumb and forefinger to see if it was going to get hot.
It burned him as soon as he touched it.
If you like the station, you will like the field iron. In fact, I have never measured it, but I think the iron on the station is close to the same voltage.

OK, I just looked at my station, and it does not have an output voltage listed, but it mentions using a wec24 pencil with that base, so I suspect that it runs off 24vac.

I also see where the 12V one is 40 watts, and the station is 60 watts. So there is a slight trade off, but when you figure that the regular pencils are in the 10 to 20 watt range, it will still do you a pretty good job.

Its much more capable than you would expect from a 12V unit.

As for original balzer, I found those crimp/solder/shrink units last night in the 50 cent range I think.
I thought that was too high so did not post the link.
I'll go back through my history and post some in a minute.
 
OK, I don't see those connectors in the 50 cent range with solder.
This outfit has them in the 67-68 cent range.
http://www.delcity.net/store/Ring-Terminals/p_791891.a_1

And this place seems to have some really nice product, along with a short video as to how to use them, but I cannot find a price on the site.

http://www.calcentron.com/Pages/elektralink/elektralink_sealed_crimp_solder_connectors.php

I found another place that has the fittings with the adhesive heat shrink without solder for a good price, but the barrels are not brazed.

I like the seam on the barrels to be brazed so it does not gap open when crimped. Even with good crimpers, there is often a stray wire sticking out of the seam when crimped if they are not brazed.

And, on both those places I linked, the non solder shrink fittings are cheaper, and with a good crimper should be as good as the solder ones.

If I were just doing repairs, I would probably use just the shrink ones, and usually do.
But, if I were doing an complete rewire, I would be tempted to go with the solder and seal ones on the theory that its best to do it right the first time and not have to redo it a couple of years down the line.

Plus, suppose you are going to have, say a 1% failure rate with crimp and say a .1% failure rate on the crimp and solder.

No idea if either of those numbers are even close.

Then, doing one repair, you have a 1 in 100 chance of a failure with just the crimp. Not bad odds.
If you are going to do 100 crimps on a rebuild, then in theory you will have a bad joint.
But, with the crimp and solder, you still have good odds of not having a bad one.
 

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