Best Way To Solder Automotive Wires

The broken wires can be repaired without replacing the entire harness or section.

Best way to solder automotive wires. The most reliable way of joining two wires together is by soldering. Crimping is an even easier process that involves requires placing the cable and connector into the crimping tool and squeezing the handle. For added insulation you can slide a piece of heat-shrink tubing about one-half inch longer than the connector over one of the wires before crimping then slide it over the finished connector and shrink using a match or lighter.

For tools Matt uses his trusty auto-stripper and an affordable soldering iron. Strip 12 inch of insulation from both wires and twist their ends tightly. Actually solder the wires.

For best results use a crimping tool but a pair of pliers will work in a pinch. The other safe connection option is the crimp connector being simple and easy to use they are popular however dont always offer the longevity of soldering. For this example we use a soldering iron to solder two 18 AWG wires together end to end.

Try to coat the wires as evenly as possible so theres a thin layer of flux on them. Tin the end of both wires by clamping them in your third hand jig and. But most automotive wiring uses 12- or 14-ga.

There is one way to twist wires together for soldering- a horizontal twist that yields a continues length of wire. Apply solder to the top until molten solder. Some times I use crimp ons.

Loom them and use a cable tie through 1 or 2 holes in the PCB to mechanically restrain them against movement. Add some flux to the wires. You also have to route and support your wires in such a way that they dont flop around.