Best method for permanently tapping wires?
 

What method do you guys prefer for taping into existing wires? When Ive done stereo installs and similar stuff, Ive used the little clamps that tap into the wire, but i dont really care for them. Ive also just cut the wire and used a butt splicer and put the new wire and one of the ends in one side.

Ive seen some people use a method where they strip some of the insulation off and solder the new wire onto it, then use heat shrink tubing or something to insulate it. This seems like the best method Ive heard of. Any other methods I should know about? I'm looking for something that'll last, and hold up to the elements.

I cut, strip, and use an open barrel splice to connect the 2 wires back together, which the new wire in there as well. Then cover with glue lined heat shrink. Makes for a near OEM quality joint that I trust more than anything else. I also have some heat shrinkable insulated butt connectors that I keep around if I need in a pinch. Just insert wires, crimp it down and apply heat. But I like the uninsulated ones better, so I can confirm it's a good crimp before I heat shrink over it.

http://uk.farnell.com/productimages/...US/4975700.jpg

I scrape of the insulation, wrap the new wire around it, and then solder in place. Since I don't cut the wire, I can't use shrink wrap. I give it two good coats of liquid electrical tape. Makes a permanent weather proof connection.

I solder it & use splicing tape. Product Catalog Scotch® Linerless Rubber Splicing Tape 130C : Electrical Commercial and Industrial: 3M US if I can't get heat shrink over it.

Still learning about wiring but the Flyin Miata Instructions for the LS swap caution against doing any soldering on the wiring.
Off the top of my head they say something about manufacturers not soldering in new wiring applications and the aircraft industry bans it as being a potential failure point.

Take it for what it is worth.

Yes FM says no soldering for the best durability but I couldn't come up with a better way so I soldered every wire I spliced. 30,000 miles later only one minor electrical issue and that was due to a bad fuel pump.

Moved post to electrical section

It's a long drawn out debate on soldering versus crimping, and each have their merits. Crimping is superior to soldering, because solder is susceptible to cracking under vibration. But that's also assuming the crimping was done with a proper crimper with the correct terminal for the wire gauge. In my opinion, use which ever method you are most comfortable with and better at. A good solder joint will outlast a fair crimp, and a good crimp will outlast a fair solder joint. If you're looking for the absolute best motorsport grade connection, then proper crimp with heat shrink is the way to go.

I'm actually surprised. I never really looked into it, but I always assumed a solder joint would be superior. Good info. I am pretty good at soldering and crimping, but Ive definitely crimped more than soldered.

Whenever crimping a pull test on the crimp joint needs completed. This test establishes the integrity of the crimp joint. Once crimp integrity gets establish the joint then will be a long lasting trouble-free joint.

Yea Ive always done the pull test. Easy way to see if it'll hold.

Ive always used these.


Ill look into getting some with heat shrink on the ends, and some with no plastic so I can crimp and use my own heat shrink.