Making Inline Splices

• 1). Clean the soldering gun's tip by wiping the hot tip with a wet soldering sponge. After removing all the dirt and oxidation with the wet sponge, "Tin" the tip by applying a fresh coating of rosin core solder. A properly tinned soldering will appear a bright silvery color.
  
  
• 2). Using the wire strippers, remove 1 inch of insulation from the wires to be spliced. Choose a length of heat-shrink tubing with an inside diameter a little larger than the outside diameter of the wires to be spliced. Cut a 2 inch piece of that heat shrink tubing and slide it over one of the wires.
  
  
• 3). Join the stripped wires together using a "Western Union" splice. To make this splice, position the stripped ends, so they cross in the center at a 45 degree angle, then twist them tightly around each other in opposite directions. Remember that every solid solder joint begins with a solid mechanical connection.
  
  
• 4). Place the hot soldering gun tip on the underside of the splice and touch the rosin core solder to the top of the splice. The solder flows around and through the splice by capillary action. The finished joint should be a bright, silvery color. A dull gray color indicates a faulty solder joint and you need to redo the joint.
  
  
• 5). Center the heat shrink tubing over the soldered splice. Plug the industrial hot air gun in and direct the hot air over the tubing. The tubing shrinks down on the splice, insulating it and making it watertight.
  
  

Installing Solderless, Crimp-on Connectors

• 1). Using the wire strippers, remove 1/2-inch of insulation from the end of the wire.
  
  
• 2). Select the proper size connector for the gauge wire being used and slide it over the stripped wire. Make sure that the bare copper is completely enclosed by the connector's insulated hub. At the same time, make sure that the wire's insulation does not get pushed inside the crimp sleeve. Getting the insulation inside the crimp sleeve causes a faulty electrical connection.
  
  
• 3). Select an opening on the crimp tool that matched the color crimp connector being used. Place the crimp tool over the crimp ring on the connector and squeeze the handles firmly together. If the color codes don't match up, you will either cut through the connector or the crimp will be loose.
  
  
• 4). Use the plastic wire ties to secure the wiring safely away from moving parts.