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Butt Splice on Main Alt B Lead

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david(at)carter.net
Guest

Posted: Fri Sep 25, 2020 6:58 am Post subject: Butt Splice on Main Alt B Lead

A couple of questionsÂ on this connection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gauge main alt B-lead wire.Â 



I didn't see any this large at Spruce, but it appears that both Amazon & AutoZone have the Dorman splices in 8 gauge. Is this a satsifactoryÂ product for our needs?Â 

https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0

Also, are there any special techniques required to ensure that the smaller wire is propertlyÂ gripped in the slice when crimped? Do I need to put some extra wire strands in there to fill the connector & snip off any excess?Â 

Thanks!

David





---

David Carter

david(at)carter.net (david(at)carter.net)

jluckey(at)pacbell.net
Guest

Posted: Fri Sep 25, 2020 8:04 am Post subject: Butt Splice on Main Alt B Lead

David,

I classify those kind of connectors as "cheap automotive" wire terminals and would not recommend them for use is aircraft.

Do a search for AMP (is Manufacturer) PIDG (Pre Insulated Diamond Grip) butt splice for something that looks like this:

[img]cid:3c50c1ed-d948-e161-0bcd-39a0b1f17789(at)yahoo.com[/img]">





Jeff Luckey

                  

                                                                    On Friday, September 25, 2020, 08:48:29 AM PDT, David Carter <david(at)carter.net> wrote:                 

                 



                 



                 A couple of questions on this connection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gauge main alt B-lead wire. 



I didn't see any this large at Spruce, but it appears that both Amazon & AutoZone have the Dorman splices in 8 gauge. Is this a satsifactory product for our needs? 

https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0

Also, are there any special techniques required to ensure that the smaller wire is propertly gripped in the slice when crimped? Do I need to put some extra wire strands in there to fill the connector & snip off any excess? 

Thanks!

David





---

David Carter

david(at)carter.net (david(at)carter.net)

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nuckolls.bob(at)aeroelect
Guest

Posted: Fri Sep 25, 2020 8:22 am Post subject: Butt Splice on Main Alt B Lead

At 09:56 AM 9/25/2020, you wrote:

  	  Quote: 	
		  A couple of questions on this connection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gauge main alt B-lead wire.Â 	


   There should be a 4AWG spread between the protected feeder

   and the fusible link stock. So the 10AWG feeder from the aux

   alternator gets a 14AWG FLW. That's the case in the

   last iteration of Z101 (rev B).

  	  Quote: 	
		   



 I didn't see any this large at Spruce, but it appears that both Amazon & AutoZone have the Dorman splices in 8 gauge. Is this a satsifactoryÂ product for our needs?Â 

  https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0 	


   The 'yellow' series PIDG terminals are indicated

   for 10-12AWG wires.



  https://tinyurl.com/y4njsbmt



   This splice would work with our favorite po' boy's

   crimp tool.



   Keep in mind that 'gas tightness' of the interface

   between wire and splice is the holy-grail. Folks

   like AMP, Molex, C-H, have spent untold bux researching

   and qualifying proven combinations of crimp dies, terminals

   and wire stranding to achieve those goals.



   Now comes wire, terminals and tools from a variety of

   sources NOT tested for playing nice in the same

   sandbox. Here are some references from the

   'Connection



  https://tinyurl.com/kfk6jss



   http://aeroelectric.com/articles/terminal.pdf



   Field history on this series of tools with PIDG has

   been favorable



  https://tinyurl.com/yy6wlbv2



 

 You might look into this alternative. The heat-shrink

 terminals and butt splices have been around for awhile



  https://tinyurl.com/y26la2p6



 . . . but no tools that produced a elegant upset of the

 wire grips without mangling the insulation . . . until

 now.



  https://tinyurl.com/y3kzobsx



 I'm ordering one of these in to take a look and try

 it out.



 

  	  Quote: 	
		  Also, are there any special techniques required to ensure that the smaller wire is propertlyÂ gripped in the slice when crimped? Do I need to put some extra wire strands in there to fill the connector & snip off any excess? 	


   You betcha. Strip the 14AWG wire back about 1/2

   and fold it so as to double the strands

   in the wire grip.



   Alternatively, you could consider a soldered lap

   joint like this



  https://tinyurl.com/yxq7c5d9



   BUT NO MATER WHICH TECHNIQUE YOU CHOSE TO EXPLORE,

   BUY EXTRA TERMINALS AND EXPERIMENT WITH THE

   PROPOSED TOOL(S) AND WIRE. DO A PULL TEST TO INSURE

   THAT YOUR WIRE/TOOL/TERMINAL COMBINATIONS ARE

   COMING TOGETHER IN BLISSFUL EMBRACE.



 

   Bob . . .

david(at)carter.net
Guest

Posted: Fri Sep 25, 2020 8:46 am Post subject: Butt Splice on Main Alt B Lead

I made a mistake in my question.Â  The main alt Â  lead is 8 gauge & joins to a 12 gauge fusible link.Â  That's the size butt connector I'm not seeing at Spruce.Â  The yellow amp goes up to 10. Â 



On Fri, Sep 25, 2020 at 12:25 PM Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:



 	  Quote: 	
		  



At 09:56 AM 9/25/2020, you wrote:

 	  Quote: 	
		  A couple of questions on this



connection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gauge



main alt B-lead wire.Ã‚ 	


Â  There should be a 4AWG spread between the protected feeder

Â  and the fusible link stock. So the 10AWG feeder from the aux

Â  alternator gets a 14AWG FLW. That's the case in the

Â  last iteration of Z101 (rev B).

 	  Quote: 	
		  Â 



I didn't see any this large at Spruce, but it appears that both Amazon



& AutoZone have the Dorman splices in 8 gauge. Is this a



satsifactoryÃ‚ product for our needs?Ã‚ 





https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0



	


Â  The 'yellow' series PIDG terminals are indicated

Â  for 10-12AWG wires.



https://tinyurl.com/y4njsbmt



Â  This splice would work with our favorite po' boy's

Â  crimp tool.



Â  Keep in mind that 'gas tightness' of the interface

Â  between wire and splice is the holy-grail. Folks

Â  like AMP, Molex, C-H, have spent untold bux researching

Â  and qualifying proven combinations of crimp dies, terminals

Â  and wire stranding to achieve those goals.



Â  Now comes wire, terminals and tools from a variety of

Â  sources NOT tested for playing nice in the same

Â  sandbox. Here are some references from the

Â  'Connection



https://tinyurl.com/kfk6jss



http://aeroelectric.com/articles/terminal.pdf



Â  Field history on this series of tools with PIDG has

Â  been favorable



https://tinyurl.com/yy6wlbv2

You might look into this alternative. The heat-shrink

terminals and butt splices have been around for awhile



https://tinyurl.com/y26la2p6



. . . but no tools that produced a elegant upset of the

wire grips without mangling the insulation . . . until

now.



https://tinyurl.com/y3kzobsx



I'm ordering one of these in to take a look and try

it out.

 	  Quote: 	
		  Also, are there any special



techniques required to ensure that the smaller wire is propertlyÃ‚ gripped



in the slice when crimped? Do I need to put some extra wire strands in



there to fill the connector & snip off any excess? 	


Â  You betcha. Strip the 14AWG wire back about 1/2

Â  and fold it so as to double the strands

Â  in the wire grip.



Â  Alternatively, you could consider a soldered lap

Â  joint like this



https://tinyurl.com/yxq7c5d9



Â  BUT NO MATER WHICH TECHNIQUE YOU CHOSE TO EXPLORE,

Â  BUY EXTRA TERMINALS AND EXPERIMENT WITH THE

Â  PROPOSED TOOL(S) AND WIRE. DO A PULL TEST TO INSURE

Â  THAT YOUR WIRE/TOOL/TERMINAL COMBINATIONS ARE

Â  COMING TOGETHER IN BLISSFUL EMBRACE.









Â  Bob . . .





	




-- 

---

David Carter

david(at)carter.net (david(at)carter.net)

Flyitnow

Joined: 05 Aug 2016
Posts: 4

Posted: Fri Sep 25, 2020 8:52 am Post subject: Butt Splice on Main Alt B Lead

Aircraft Spruce # 320570

                  

                                                                    On Friday, September 25, 2020, 09:34:01 AM PDT, Jeff Luckey <jluckey(at)pacbell.net> wrote:                 

                 



                 



                 

         David,



I classify those kind of connectors as "cheap automotive" wire terminals and would not recommend them for use is aircraft.



Do a search for AMP (is Manufacturer) PIDG (Pre Insulated Diamond Grip) butt splice for something that looks like this:



[img]cid:QnZ7yPtZMT5FlqyPCsTE[/img]">



Jeff Luckey



                  

                                                                    On Friday, September 25, 2020, 08:48:29 AM PDT, David Carter <david(at)carter.net> wrote:                 

                 

                 

                 A couple of questions on this connection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gauge main alt B-lead wire. 

I didn't see any this large at Spruce, but it appears that both Amazon & AutoZone have the Dorman splices in 8 gauge. Is this a satsifactory product for our needs? 

https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0



Also, are there any special techniques required to ensure that the smaller wire is propertly gripped in the slice when crimped? Do I need to put some extra wire strands in there to fill the connector & snip off any excess? 



Thanks!

David

---David Carterdavid(at)carter.net (david(at)carter.net)

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Mauledriver(at)nc.rr.com
Guest

Posted: Fri Sep 25, 2020 9:03 am Post subject: Butt Splice on Main Alt B Lead

You would need crimping equipment of       the right size in order to use a crimp type splice.Â  Even assuming       a quality connector is available, doing it once or twice may not       justify getting the crimping equipment required or gaining the       practice needed to do it 100% effectively.

     

     

     I'd suggest a solder type butt       connector sized for 10guage and then stuffing the 12 guage side       with extra strands as required.Â  All you need is solder and a       torch to get it done.Â  Big item like that is easier technique-wise       than smaller solder work.

     

     

     Bill "just a another amateur wire       splicer with an opinion" Watson

     

     

     

     On 9/25/2020 10:56 AM, David Carter       wrote:

     

      	  Quote: 	
		                A couple of questionsÂ on this connection. Z101         calls for a 12-gauge FLW butt spliced onto the 10-gauge main alt         B-lead wire.Â          

         

         I didn't see any this large at Spruce, but it appears that           both Amazon & AutoZone have the Dorman splices in 8 gauge.           Is this a satsifactoryÂ product for our needs?Â 

         https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0

         

         

         Also, are there any special techniques required to ensure           that the smaller wire is propertlyÂ gripped in the slice when           crimped? Do I need to put some extra wire strands in there to           fill the connector & snip off any excess?Â 

         

         

         Thanks!

         David

         

         

         

         

                                 ---

               David Carter

               david(at)carter.net (david(at)carter.net)

           

         

       

     	
     



            	 		 			 				 			 		 		 			

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jluckey(at)pacbell.net
Guest

Posted: Fri Sep 25, 2020 11:15 am Post subject: Butt Splice on Main Alt B Lead

David,

See if this meets your needs....

Heat Shrink, Crimp Seal Butt Connectors



<![endif]--><![endif]-->$7.73

<![endif]-->Heat Shrink, Crimp Seal Butt Connectors

Heat Shrink, Crimp Seal Butt Connectors

                  

                                                                    On Friday, September 25, 2020, 10:38:51 AM PDT, David Carter <david(at)carter.net> wrote:                 

                 



                 



                 I made a mistake in my question.  The main alt   lead is 8 gauge & joins to a 12 gauge fusible link.  That's the size butt connector I'm not seeing at Spruce.  The yellow amp goes up to 10.  

On Fri, Sep 25, 2020 at 12:25 PM Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:

 	  Quote: 	
		  At 09:56 AM 9/25/2020, you wrote: 	  Quote: 	
		  A couple of questions on thisconnection. Z101 calls for a 12-gauge FLW butt spliced onto the 10-gaugemain alt B-lead wire.Ã‚ 	
  There should be a 4AWG spread between the protected feeder  and the fusible link stock. So the 10AWG feeder from the aux  alternator gets a 14AWG FLW. That's the case in the  last iteration of Z101 (rev B). 	  Quote: 	
		   I didn't see any this large at Spruce, but it appears that both Amazon& AutoZone have the Dorman splices in 8 gauge. Is this asatsifactoryÃ‚ product for our needs?Ã‚ https://www.autozone.com/miscellaneous-non-automotive/electrical-wire-connector/dorman-conduct-tite-8-gauge-butt-connectors/422502_0_0 	
  The 'yellow' series PIDG terminals are indicated  for 10-12AWG wires.https://tinyurl.com/y4njsbmt  This splice would work with our favorite po' boy's  crimp tool.  Keep in mind that 'gas tightness' of the interface  between wire and splice is the holy-grail. Folks  like AMP, Molex, C-H, have spent untold bux researching  and qualifying proven combinations of crimp dies, terminals  and wire stranding to achieve those goals.  Now comes wire, terminals and tools from a variety of  sources NOT tested for playing nice in the same  sandbox. Here are some references from the  'Connectionhttps://tinyurl.com/kfk6jsshttp://aeroelectric.com/articles/terminal.pdf  Field history on this series of tools with PIDG has  been favorablehttps://tinyurl.com/yy6wlbv2You might look into this alternative. The heat-shrinkterminals and butt splices have been around for awhilehttps://tinyurl.com/y26la2p6. . . but no tools that produced a elegant upset of thewire grips without mangling the insulation . . . untilnow.https://tinyurl.com/y3kzobsxI'm ordering one of these in to take a look and tryit out. 	  Quote: 	
		  Also, are there any specialtechniques required to ensure that the smaller wire is propertlyÃ‚ grippedin the slice when crimped? Do I need to put some extra wire strands inthere to fill the connector & snip off any excess? 	
  You betcha. Strip the 14AWG wire back about 1/2  and fold it so as to double the strands  in the wire grip.  Alternatively, you could consider a soldered lap  joint like thishttps://tinyurl.com/yxq7c5d9  BUT NO MATER WHICH TECHNIQUE YOU CHOSE TO EXPLORE,  BUY EXTRA TERMINALS AND EXPERIMENT WITH THE  PROPOSED TOOL(S) AND WIRE. DO A PULL TEST TO INSURE  THAT YOUR WIRE/TOOL/TERMINAL COMBINATIONS ARE  COMING TOGETHER IN BLISSFUL EMBRACE.

  Bob . . .

	


-- ---David Carterdavid(at)carter.net (david(at)carter.net)

nuckolls.bob(at)aeroelect
Guest

Posted: Fri Sep 25, 2020 11:31 am Post subject: Butt Splice on Main Alt B Lead

At 11:41 AM 9/25/2020, you wrote:

  	  Quote: 	
		  I made a mistake in my question.Â  The main alt Â  lead is 8 gauge & joins to a 12 gauge fusible link.Â

 That's the size butt connector I'm not seeing at Spruce.Â  The yellow amp goes up to 10. Â 	


  Crimp tools in that size are not commonly

  available. I think I'd go for a soldered lap-joint

  for that one.



 

   Bob . . .

david(at)carter.net
Guest

Posted: Fri Sep 25, 2020 1:03 pm Post subject: Butt Splice on Main Alt B Lead

Yes, I was leaning toward the soldered lap joint approach. I considered crimping ring terminals on each wire end & joining them with a 1/4" bolt/nut assembly, but the 8-gauge crimper again becomes a problem.Â 



Thanks to all for the advice & ideas.Â 

---

David Carter

david(at)carter.net (david(at)carter.net)



On Fri, Sep 25, 2020 at 3:37 PM Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:



 	  Quote: 	
		    At 11:41 AM 9/25/2020, you wrote:

  	  Quote: 	
		  I made a mistake in my question.Ã‚Â  The main alt Ã‚Â  lead is 8 gauge & joins to a 12 gauge fusible link.Ã‚

 That's the size butt connector I'm not seeing at Spruce.Ã‚Â  The yellow amp goes up to 10. Ã‚ 	


 Â Crimp tools in that size are not commonly

 Â available. I think I'd go for a soldered lap-joint

 Â for that one.



 

 Â  Bob . . .

DougW

Joined: 16 Sep 2015
Posts: 14
Location: Washington

Posted: Fri Sep 25, 2020 3:50 pm Post subject: Butt Splice on Main Alt B Lead

Don’t know if these butt connectors would be of use here, but I am curious what Bob thinks.  This URL goes to a Summit Racing site and shows that application.  Looks pretty slick to me.

 

https://tinyurl.com/y374wd4m

 

Doug Windhorn

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of Robert L. Nuckolls, III

Sent: Friday, September 25, 2020 10:02 AM

To: aeroelectric-list(at)matronics.com

Subject: Re: Butt Splice on Main Alt B Lead

 

At 11:41 AM 9/25/2020, you wrote:



 	  Quote: 	
		  

I made a mistake in my question.Â  The main alt Â  lead is 8 gauge & joins to a 12 gauge fusible link.Â

That's the size butt connector I'm not seeing at Spruce.Â  The yellow amp goes up to 10. Â 	




 Crimp tools in that size are not commonly

 available. I think I'd go for a soldered lap-joint

 for that one.



  Bob . . .

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