What are the basic techniques for making wire-to-wire connections?

Answer 1

There are several techniques for making wire connections, but one of the most important steps is done before actually making the connection. The key to a good connection, regardless of connection method, is that the wires [conductors] MUST BE as CLEAN AS POSSIBLE. All metal wire is subject to corrosion due to exposure to Oxygen and contaminates in the air. The oxides and salts in the corrosion have a higher resistance to electrical current flow than the clean, uncorroded/uncontaminated metal. This material must be removed to reduce resistance in the connection. This can be accomplished by scraping with a sharp blade, or "sanding' with some type of abrasive paper, or even an emory board. When clean, the wire will be bright and shiney. Also common to making all connectoions is that some of the insulation on the wires must be removed to allow metal to metal contact. This process is generally called "stripping." The amount of insulation to be stripped varies slightly depending on the connection method, but usually requires about 1/4 inch to 3/8 inch [minimum], to as much as 1/2 inch. There are several different mechanical stripping tools available, but the most common tool used is the same knife to be used in cleaning the conductor. An important key in stripping is that the wire conductor MUST NOT be "knicked," subjecting it to future fracture failure. As to making the actual connection of the clean conductors, there are several methods, the description of which follows. 1. The simplest method is to hold the wires together, with the ends even, and tightly twist the bare conductors together, with the twist beginning at the edge of the insulation, and continuing to the ends of the conductors. This is THE most basic connection. Another requirement common to this and all other types of connection is that, after the connection is made, it is necessary to insulate the bare wires to prevent them from coming into contact with other connections OR any grounded metal. The simplest reinsulating method is to wrap the connection, and an inch or so of the adjacent insulated portion of the wires with "Electrical Tape." In addition to insulating the connecting joint, it also provides slight mechanical reinforcement of the "relatively" weak twisted connection. The next improvement in the method of mechanical strengthening and insulation of the joint is the use of one of several "wire nut" connectors which both insulate and add significant mechanical strength. 2. Another method of strengthening the twisted connection is to "solder" the connection with a heat fusible metal, which also, seals the twisted connection from exposure to the air, thus reducing the redevelopment of more corrosion due to exposure to moisture and contaminates. 3. The final of the basic techiniques is the use of mechanical clamp type connectors of which there are two basic types. The connector that has been around the longest is basically a small "bolt" which has a hole through it for inserting the wires, which is then then mechanically secured with a nut. The other purely mechanical device is what is called a "Crimp" type connector. The crimp connector is basically a metal sleeve into which the wires are inserted, followed by crimping, or "pinching" the connector tightly around the wires. The crimping is properly done using a special pair of pliars designed to accomplish the unlimate connection. In an emergency, it is possible to make the crimp with ordinary pliars. There are several more methods for making wire-to-wire connections, but these are the basic ones.