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Old 30 April 2014, 09:57   #11
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nothing wrong with joining cables the problems arise when cables are joined badly

make a good job of it & it will be fine

company I work for supply diver operated dredgers which run 440v motors subsea if a cable gets damaged we cut it, crimp & solder then pot the repair & happily send the cable down to 200m for the divers to use that's 20 bar of pressure & life threatening voltage

I'm sure if we can do that you can do a suitable joint inside your console

as said previously crimp,solder & good insulation are the way to go

I wouldn't want to waste 100 worth of cables
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Old 30 April 2014, 11:46   #12
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Originally Posted by colcreate View Post
Soldering was once an accepted method of connecting cables in aircraft, there was a standard written for it and training for it's correct implementation.

I'm long since removed from that industry but was surprised to learn that what was once considered best practice is now (6 years ago) considered illegal. Who, when and why?
Likely the same reason the ABYC (American Boat and Yacht Council?) has gone against it: Soldering creates a "hard" spot in the wiring that tends to focus any flex on the adjacent section of wire. Under vibration, those areas tend to fail.

Personally, I don't see a whole lot of difference between the hardening from soldering, or the hardening from crimping a connector on, but that's what they suggest.

jky
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Old 30 April 2014, 19:50   #13
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ABYC standards only prohibit soldering as the sole means of making a connection, they don't however exclude the use of soldering a butt connector and suggest the use of 60%/40% solder alloy.
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Old 01 May 2014, 13:11   #14
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Quote:
Originally Posted by beamishken View Post
nothing wrong with joining cables the problems arise when cables are joined badly



make a good job of it & it will be fine



company I work for supply diver operated dredgers which run 440v motors subsea if a cable gets damaged we cut it, crimp & solder then pot the repair & happily send the cable down to 200m for the divers to use that's 20 bar of pressure & life threatening voltage



I'm sure if we can do that you can do a suitable joint inside your console



as said previously crimp,solder & good insulation are the way to go



I wouldn't want to waste 100 worth of cables

Happily this is also the view of a local marine engineer. He is coming round to crimp, solder and heat shrink it next week. Reckons that since the existing cables are so new, done properly with the correct crimping tool, the joint will last as long as the cable, Happy Days.
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Old 01 May 2014, 18:41   #15
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replace the cables...

I've had a bad experience with well connected cables.

I guess Beamisken's solution for joining the cables is the best way to join cables - ie soldering the cables and potting the joints in resin - BUT - its not easy for an amateur to properly solder a joint on 16mm cable, and potting the joints in resin isn't difficult - it mightn't be obvious to an amateur what kit to buy, and where to buy it.

I'd say just bite the bullet and replace the cables with new cables of the right length - or even - a bit longer then the right length.

It'll probably save you from heartbreak with engine starting or cutting out problems down the road...

'Been there - bought the new starter'...
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Old 02 May 2014, 03:49   #16
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Nothing wrong with extending battery cables provided it's done properly:-
- Get an auto electrician to advise the cable size you need for the new length of run(longer run = bigger cable). If your existing cables aren't at least this big you'll need to replace.
- Assuming you have standard 'ring' terminals crimped (properly) into your existing cables, get new extensions made up with matching 'ring' terminals. Crimp them on properly using the correct tool.
- bolt the new sections onto the old using stainless bolts, having cleaned up both sides of the terminals to a shiny finish first. Cut the bolts flush with the nuts after tightening and file off any sharp edges.
- Fully insulate the joints with self-amalgamating tape or ideally better still adhesive heat-shrink tubing. Use a couple of layers to be sure.
- Secure the cables so the joints can't chafe against anything and definitely not against eachother.
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Old 10 May 2014, 19:04   #17
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Had the cable extensions put in this week and took it for a bounce round the Calf of Man today. Checked them afterwards and it all seems nice and secure with no signs of flexing or chafing on the heat seal. Let's hope it stays that way.
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