how end-join wires?

[simonbaker]

Is there a nifty way to end-join wires?

I'm making a usb "crossover" cable so I can connect coils made with red-black wires for RX coil to PCB that assumes green-white wires for RX coil.

Just haven't found a convenient technique to end-join two sets of wires without a lot of hassle. For now, careful twisting, soldering, cussing...

-SB

[Stefan]

Joining wires.

There is an easy way which makes a neat joint.

Take one of the small strands from a multi strand cable. The wire could be say 0.1 mm diam for example.

Butt the two wires you want to join so that there is an overlap of say 10mm. Then use the multi strand wire and wind over the overlap about 6 or 7 times so that the joint is now held together with the thin wound wire. Now carefully solder the joint. You now end up with a neat solder joint and with heat shrink applied a professional job.

Stefan

[simonbaker]

There is an easy way which makes a neat joint.

Take one of the small strands from a multi strand cable. The wire could be say 0.1 mm diam for example.

Butt the two wires you want to join so that there is an overlap of say 10mm. Then use the multi strand wire and wind over the overlap about 6 or 7 times so that the joint is now held together with the thin wound wire. Now carefully solder the joint. You now end up with a neat solder joint and with heat shrink applied a professional job.

Stefan

Ah, I knew there must be a better way. However, with a close bundle like a USB cable, sounds a little tricky to wind that wire.

I was wondering if a little copper foil crimped could work also (not that I have any).

Regards,

-SB

[homefire]

I use small metal tubing for but connectors.

[simonbaker]

I use small metal tubing for but connectors.

Sounds interesting -- what tubing?

-SB

[Stefan]

Crimping will do an easier job but if you can't get the small crimps or copper tube this method will work. With the USB cable in the photo, a normal cable repair would stagger the joints over 30 to 40 mm so the cable joints do not bunch up at one location. I see in the photo that the bunching is evident. Stagger the joints and the repair of even multi core cables will be easy.

Stefan

[WM6]

There is an easy way which makes a neat joint.

Take one of the small strands from a multi strand cable. The wire could be say 0.1 mm diam for example.

Butt the two wires you want to join so that there is an overlap of say 10mm. Then use the multi strand wire and wind over the overlap about 6 or 7 times so that the joint is now held together with the thin wound wire. Now carefully solder the joint. You now end up with a neat solder joint and with heat shrink applied a professional job.

Stefan

Hi Stefan, can you put some drawings here about?
Thanks

[simonbaker]

Crimping will do an easier job but if you can't get the small crimps or copper tube this method will work. With the USB cable in the photo, a normal cable repair would stagger the joints over 30 to 40 mm so the cable joints do not bunch up at one location. I see in the photo that the bunching is evident. Stagger the joints and the repair of even multi core cables will be easy.

Stefan

Nice idea to make it neater -- but a little more effort.

Any ideas on "strain relief" for end joins would be useful too.

Seems like an area ripe for invention.

Also need for shrink tube that can be put on after the join -- that would be handy.

-SB

[DOOLEY]

a company called "raychem" i think produce heat shrink tubing with a glue inside , in all sorts of sizes ,

so as in picture above , slip on a cut tube over one of the outer cables , and also on the center wires ,

then join individual wires by "sliding strands" togeter then twist slightly to hold and solder straight away , slide tube into middle and warm to shring until glue apears at each end.

repeat till all wires done.
then use insulation tape to "pack out" the wires so they are the same diameter as the original covering , then slide over the outer tube alowing 10mm or so min overlap on the original shief , warm to shrink and till the glue comes out , wipe off the glue straight away.

this is a way to acheave a profesional looking and strong joint , also water tight.

[simonbaker]

a company called "raychem" i think produce heat shrink tubing with a glue inside , in all sorts of sizes ,

so as in picture above , slip on a cut tube over one of the outer cables , and also on the center wires ,

then join individual wires by "sliding strands" togeter then twist slightly to hold and solder straight away , slide tube into middle and warm to shring until glue apears at each end.

repeat till all wires done.
then use insulation tape to "pack out" the wires so they are the same diameter as the original covering , then slide over the outer tube alowing 10mm or so min overlap on the original shief , warm to shrink and till the glue comes out , wipe off the glue straight away.

this is a way to acheave a profesional looking and strong joint , also water tight.

Good to know about, thanks!

-SB

[DOOLEY]

it's a mechanic thing , we use it for any external wiring , strong and water proof perminent repair , and a must for under trailers where water and grime spray up , if i see standard insulation tape used obscenities are spoken loudly !!

recomended as warranty standard after market repair by car manufacturers.

first discovered the stuff working for citroen 20 years ago ,

unsure if raychem is available worldwide though.

[Alexismex]

Thanks Dooley for this good info because i have see it in many catalog but i say" bofff shrink tubing with glue ... crazy thing"
I will buy soon this... thank to you.
Alexis.

[satdaveuk]

Is there a nifty way to end-join wires?

I'm making a usb "crossover" cable so I can connect coils made with red-black wires for RX coil to PCB that assumes green-white wires for RX coil.

Just haven't found a convenient technique to end-join two sets of wires without a lot of hassle. For now, careful twisting, soldering, cussing...

-SB

Hi Simon everything is good with the cable joining apart from the inner cables need to be cut at different lenths so you end up with staggered joints for double protection against shorts/emf problems.
Its something I learned when serving my time.
All the best mate
Dave

[DOOLEY]

good point , staggered joints , i do this to avoid the "LUMP" in the middle , and allways do this when joining mains / ac cables fo added saftey.

not allways possible if joining more than 4 or 5 cores as joint length increaces.

[J_Player]

Hi Simon everything is good with the cable joining apart from the inner cables need to be cut at different lenths so you end up with staggered joints for double protection against shorts/emf problems.
Its something I learned when serving my time.
All the best mate
Dave

I also have always used staggered joints. I usually put a shrink tube on each joint before soldering.
When I'm done I have a lump, but not as bad as when no staggering.
I Also slit the outer sheath farther than needed, and slide a large shrink tube over it first.
Then when all the inner tubes are shrunk, I close back the outer sheath and ground over them and slide the big shrink tube in place to finish the shrinking operation.

For High power splices, I always use electrical tape with many wraps and a big lump, to avoid the possibility of conductors poking through thin pvc shrink tubing.

Best wishes,
J_P