What method to use for Joining 6 Awg with 10Awg

[Andyfender]

What is a good method of joining 6 awg and 10 awg? I do not think there is a butt splice connector that size. So I think my only option is to solder them and then wrap heat shrink around it? Any other ideas?

Andy

 

[bruceb58]

Re: What method to use for Joining 6 Awg with 10Awg

Probably your only option.

 

[haulnazz15]

Re: What method to use for Joining 6 Awg with 10Awg

You can buy terminal blocks/distributers for this purpose. They are used heavily in car audio to distribute power to several amps.

 

[cwhite6]

Re: What method to use for Joining 6 Awg with 10Awg

You can buy terminal blocks/distributers for this purpose. They are used heavily in car audio to distribute power to several amps.

I was about to say the same thing. Here is a whole slew of them off of iboats.

http://www.iboats.com/Marine-Power-...4291194--**********.350868635--view_id.469666

Make sure you get one with a stud connector big enough that a 6awg ring lug will fit on. I have also seen these with covers for sale.

 

[Silvertip]

Re: What method to use for Joining 6 Awg with 10Awg

A question I have is "why" are you joining a smaller gauge wire with a larger gauge? On one hand it may not be important but on the other it is very important. Just trying to help avoid a mistake. As for the process, slip a couple sizes of heat shrink tubing over the wires. Solder them and then seal with two or three layers of heat shrink.

 

[Andyfender]

Re: What method to use for Joining 6 Awg with 10Awg

A question I have is "why" are you joining a smaller gauge wire with a larger gauge? On one hand it may not be important but on the other it is very important. Just trying to help avoid a mistake. As for the process, slip a couple sizes of heat shrink tubing over the wires. Solder them and then seal with two or three layers of heat shrink.

I called Minn Kota and they suggested I use 6awg wire to join up with the 10awg from the trolling motor.

Andy

 

[Riverboat_Mickey]

Re: What method to use for Joining 6 Awg with 10Awg

Any other ideas?

A simple sheet bend should do the trick!

Sorry... couldn't help myself! Carry on!

- Mike

 

[fishrdan]

Re: What method to use for Joining 6 Awg with 10Awg

I don't think you should plain solder them together as there is no mechanical connection, if the wire gets hot enough to melt the solder the wires are coming apart. Here's a couple idea's;

Melt the insulation off a 6AWG butt connector, crimp that onto both wires then solder and (double) heat shrink the connection. If possible, double over the 10AWG wire before inserting it into the butt connector, so 2x the 10AWG wire in the butt connector.

Crimp the proper sized ring terminal onto each wire, then attach both of the wires with a short SS screw and nut. Double heat shrink over the entire connection. Kind of like a terminal block,, without the block.

If you can find a butt connector big enough to slide both wires into one side, yet still snug, knock the center stop out of the butt connector, slide the 6AWG all the way through and then the 10AWG all the way through from the other side, crimp, solder and heat shrink. This will be a PITA as you need to open the center of the butt connector to the same size as the ends (drill). This is how I had my old trolling motor wires, hard wired, to the 6AGW battery wires.

Edit: saw it was for a trolling motor. You can also use a trolling motor plug/receptacle.

http://www.iboats.com/2-Wire-ConnectPro-trade-Charging-Trolling-System-Trolling-Motor-Plug-Receptacle-Marinco/dm/*******.040879944--**********.562428164--view_id.391342

 

[Andyfender]

Re: What method to use for Joining 6 Awg with 10Awg

The receptacle is the best way to go for me.

Thanks,

Andy

 

[H20Rat]

Re: What method to use for Joining 6 Awg with 10Awg

get a car audio power distribution block, NOT a ring terminal block. The car audio stuff will have a set screw that secures the wire directly into the block. With a regular ring terminal block you will have twice as many connections, twice as many points to fail or corrode, and quite a bit more resistance. (wire to ring connector, connector to terminal, and then 2 more on the other side. The distribution block will only have wire->block->wire)

Most ring terminal blocks also have exposed metal that is hot, not TOO much of an issue in a boat environment but still a concern.

 

[iBrent]

Re: What method to use for Joining 6 Awg with 10Awg

I don't think you should plain solder them together as there is no mechanical connection, if the wire gets hot enough to melt the solder the wires are coming apart.

This is incorrect. Properly soldered connections are usually electrically better than strictly mechanical connections. Plus, solder generally reflows at about 180C (360F). If you are seeing these temperatures on the wires then you have much bigger problems.

Soldering would be best, but with that gauge wire it would definitely not be easy.

 

[Wishiniwuzfishin]

Re: What method to use for Joining 6 Awg with 10Awg

Not sure if you need a straight connection or if looks are important but how about a wire nut? Exactly what they are made for and you can pick the exact size.

 

[fishrdan]

Re: What method to use for Joining 6 Awg with 10Awg

This is incorrect. Properly soldered connections are usually electrically better than strictly mechanical connections. Plus, solder generally reflows at about 180C (360F). If you are seeing these temperatures on the wires then you have much bigger problems.

Soldering would be best, but with that gauge wire it would definitely not be easy.

USCG regulations state that soldering should not be the sole means for an electrical connection. You need a mechanical connection (crimp) first, then you can solder if you want to. I crimp and solder, others just crimp.

(Oh boy, here comes the crimp vs crimp and solder debate..................)

 

[bruceb58]

Re: What method to use for Joining 6 Awg with 10Awg

The biggest problem here is finding a crimper and the butt crimps to join 10 to 6. If he has only one wire, then solder will be fine for this application.

As many know, I am a "crimp only" person. No solder. And using solder on a crimp defeats the whole purpose of the crimp in the first place. Why would you use a butt joint crimp if you were going to go ahead and solder...doesn't make any sense at all.

 

[fishrdan]

Re: What method to use for Joining 6 Awg with 10Awg

Crimp and solder makes perfect sense for the average DIYer, crimp to make a mechanical connection that will not pull apart and satisfy the USCG regulation, then solder to make a connection that will not corrode. While this might not be perfect, I don't see the average person being able to make a better electrical connection without the use of expensive crimps and expensive crimp pliers, which most people won't buy.

 

[bruceb58]

Re: What method to use for Joining 6 Awg with 10Awg

Fishrdan,

So what are you recommending here? Find a reducing crimp that goes from 10 to 6. Remove the insulation on the crimp. Crimp with some sort of tool. Solder and then add shrink wrap.

My point is why even bother with the crimp if you are going to solder anyway.

 

[rjwoodrome]

Re: What method to use for Joining 6 Awg with 10Awg

just use the blue wire nuts, they are big enough, and will take the temperature and will stay on if you twist the wires first. there is also an item called a polaris connector sold in any electrical supply. they are a set screw connector covered by rubber and are awesome.

 

[bruceb58]

Re: What method to use for Joining 6 Awg with 10Awg

just use the blue wire nuts, they are big enough, and will take the temperature and will stay on if you twist the wires first.

LOL...that's pretty funny.

 

[Silvertip]

Re: What method to use for Joining 6 Awg with 10Awg

I suggest one do a little "pull test" on a #6 to #10 butt splice. You need a butt connector that will fit the #6 which will be too large for a proper crimp on the #10. That joint will pull apart. A properly soldered joint is electrically sound, physically strong and will work just fine. And melting the joint is utterly rediculous! There are much more serious implications if the wires get that hot.

 

[Andyfender]

Re: What method to use for Joining 6 Awg with 10Awg

What about using screw through ring connectors?