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Thread: FAQ: Proper Wire Termination and Connection Methods

  1. #1
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    FAQ: Proper Wire Termination and Connection Methods

    After the recent influx of shoddy wiring showing up on these boards I feel that it is imperative to have a FAQ regarding proper termination and connection techniques.

    I'll start off with this critical link:

    http://www.mmxpress.com/technical/connections.htm

    Earmark is a premier Car Audio shop here in the D/FW area in Texas.

    This is taken directly from their page: http://www.earmarkcaraudio.com/install_default.asp

    EARMARK performs every electrical connection of every installation with solder and heatshrink. This means if we install it, it's going to operate trouble-free. No crimps, spacecaps, scotchlocks, butt connectors or twisted and taped wires that eventually fail.
    This is from a company that provides a lifetime warranty on everything they do. There is a reason they do things the way they do.

    While my husband worked at Circuit City as an Instillation and Sales manager for the Car Audio portion of numerous stores in the College Station and Dallas area, he and his co workers took pictures of various poor wiring jobs that they ran across from other stores and from individuals brining their cars in to have things done properly.

    Here are some of their pics:

    Poor Wiring:


    Rewired properly


    Improper Hood pin install for an alarm:


    Stereo wires not even secured under the hood:


    Alarm brain and all the wiring - what a mess:




    Wow - not even sure what to say here, bare, exposed wire, among other things.


    Properly installed...so much prettier, much less likely to be damaged in every day use, much less likely to fall apart, much less of a fire hazard, and much more likely to work right.


    Sometimes, you need to contort to get into the right position to work.


    I plan on taking some pics on soldering techniques sometime soon. If anyone else would like to add, please feel free.
    Jan Bennett
    FS: VW MKIV Bezel for 8" Lilliput - 95% Finished

    Please post on the forums! Chances are, someone else has or will have the same questions as you!

  2. #2
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    Jan Bennett
    FS: VW MKIV Bezel for 8" Lilliput - 95% Finished

    Please post on the forums! Chances are, someone else has or will have the same questions as you!

  3. #3
    Raw Wave kickercivic1's Avatar
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    Quote Originally Posted by Red GTi VR6
    Alarm brain and all the wiring - what a mess:
    Mine was done at so called "authorized" dealer and looks like this picture.

  4. #4
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    Test your soldering knowledge: http://www.autoshop101.com/tests/intest7.html

    http://www.popularmechanics.com/auto...tml?page=3&c=y

    http://www.mmxpress.com/technical/connections.htm
    Jan Bennett
    FS: VW MKIV Bezel for 8" Lilliput - 95% Finished

    Please post on the forums! Chances are, someone else has or will have the same questions as you!

  5. #5
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    Quote Originally Posted by kickercivic1
    Mine was done at so called "authorized" dealer and looks like this picture.
    My husband spent a good part of his management with Circuit City as the manager that fixed other stores problems. He was so good at it that CC would specifically send him to other stores to essentially fire everyone and start new with competent installers and would fix the stores problems.

    This was one of the instances.

    There will always be bad installers. You just need to know what to look for and how to pick out good installers.
    Jan Bennett
    FS: VW MKIV Bezel for 8" Lilliput - 95% Finished

    Please post on the forums! Chances are, someone else has or will have the same questions as you!

  6. #6
    Raw Wave kickercivic1's Avatar
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    I am getting the the 791xv installed, soon, but i want to completely uninstall my 561xv or whatever. I have no clue where to start from tho.

  7. #7
    Maximum Bitrate DJiK's Avatar
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    To help Red with her quest, here are some pics from my latest wiring job in the car.

    Breif history: the wires running from the car to the trunk's lid were poorly designed by the Audi engineers in my car's model.
    Whenever the trunk would open/close, it'd stress the wires out by over-stretching them.
    They got to a point of snapping. By the time I noticed it, 6 out of 8 wires were torn apart.

    Pics:
    Before


    During


    After


    Summary:
    Every wire was extended by a few more mm's.
    The same gauge size was used.
    There are two soldering points to each wire (1 at either end) and a tubes of heat-shrink applied to each soldering point.
    As seen in the last pic, the whole wire bundle is covered with two large heat-shrink tubes and routed around the joint with zip-ties.
    For Sale: Carputer (CarPC) & RCA Y-Adapter
    Newsflash: Take a look at my unsold stuff above, thanks!
    Up Next: Make an OBD to Serial cable & Redo the "MMI buttons"

  8. #8
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    very nice!
    Jan Bennett
    FS: VW MKIV Bezel for 8" Lilliput - 95% Finished

    Please post on the forums! Chances are, someone else has or will have the same questions as you!

  9. #9
    Constant Bitrate racerx3165's Avatar
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    There will always be a grey area when it comes to connections but i will say this the more work it takes to make the connection the better it usually seems to be. Personally i would never use a solder-less crimp in anything i have seen so many of these cause noise / and pull out with minimal force. So imo solder with some heat shrink is the only way, and since i was fortunate enough to attend a high reliability soldering class the AF offered i am somewhat ok at it
    Cars
    1994 Mustang GT Punch 240.4 2 12" Kicker Comp SOLD :(

    2006 Suzuki Aerio Sx Kicker KX 650.4 RE 10

    2003 Eddie Bauer Expedition DVD - Navigation Package Traded in for 2008 XL-7 Limited

    Car PC
    Planning

  10. #10
    Constant Bitrate
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    I have given up on solderless connections to. I have used all sorts, and though most work for standard setups/simple devices I don't like doing it. Everything outside the cab is soldered for sure. Mainly because of conditions and stress/vibrations. Inside the cab I started doing it because of shorts and so on. It is all worth the time.

    Brent
    1999 Nissan SE-L - turbo toy
    1993 Nissan NX - Turbo Racer

    Standalone fuel management (AEM EMS) on both
    carPC

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