Splicing 6-gauge wire

[Deadmeat]

I'm in the final stages of doing some boat mods and had a senior moment yesterday. I ran 6-gauge wire from the trolling motor on the deck to the rear of the boat and had some left over. I measured where the battery was going to go and cut the positive wire to length. Then I decided to re-route the wire to a more protected area. Big mistake. Now it's about a foot too short but it's already been cut and I need to splice in a piece of 6-gauge wire to get it to the positive terminal. I made a run to Home Depot and Lowe's but couldn't find anything to make the splice. I couldn't find any butt connectors that were big enough. Yes, I could go back to my original plan and have enough to do the job but I'd rather not if I can find a way to make this work. Can anyone out there tell me how to make the splice?

 

[Captain Ahab]

You probably woudl want to use something like this:

That you can purchase here:

https://www.grainger.com/Grainger/b...s/electrical/ecatalog/N-8hxZ1z1025s?op=search

 

[crazymanme2]

` I usually have numerous sizes of copper tubing around so I'll find the right size & use that & solder.Either shrink tube it or use hot glue gun to make it water proof.I also use copper tubing when I need a connector on the end of a wire.Flatten end of copper tubing,drill hole,than solder wire to other end of tubing.

 

[Deadmeat]

I'm confused. Why do you drill a hole in the copper tubing?

 

[crazymanme2]

Sorry if I confused you.To make this kind of connector.I was explaining other ways to use copper tubing other than for splicing.

 

[Deadmeat]

Ah, now I understand. Thanks.

 

[danmyersmn]

That is a great idea to use copper tubing then shrink tubing over it. I don't know if you can find copper tubing small enough? Maybe take a piece of 1/4" and slice a cut in the length of it so that it can overlap itself to become small enough for the wire. Other then that it should work perfect and I know I will remember that solution when I need to solve the same problem.

 

[crazymanme2]

You can get copper tubing down to 1/8 inch.How small do you need it :?:

 

[Deadmeat]

Don't know about him but I need it the right size to cram in a 6-gauge wire from each end. Great idea and thanks.

 

[redbug]

no matter what type of splice you use it will cause a drop in voltage and performance.
it might only be a slight drop but it will drop off.

 

[Truckmechanic]

` I usually have numerous sizes of copper tubing around so I'll find the right size & use that & solder.Either shrink tube it or use hot glue gun to make it water proof.I also use copper tubing when I need a connector on the end of a wire.Flatten end of copper tubing,drill hole,than solder wire to other end of tubing.

Now I know I belong here...this is the same things I do.


This is the way I would repair the wire, if it was coming from the battery directly i would probably use 2 peices of shrink just to be safe.

 

[Captain Ahab]

no matter what type of splice you use it will cause a drop in voltage and performance.
it might only be a slight drop but it will drop off.

Correct! And if it is not done correctly you will also cause a "hot" spot that can melt the insulation (or worse)

 

[jdd5p]

You could use a split bolt connector. You can find them at Lowe's, or anywhere that has electrical supplies.

 

[redbug]

You could use a split bolt connector. You can find them at Lowe's, or anywhere that has electrical supplies.

Split bolts are junk dont waste the money....

 

[Oddagus]

I guess I have made thousands of splices in my career and nothing beats the correct connector, the right crimping tool, and adhesive filled heat shrink. The voltage drop in DC wiring is considerable and that can cause trouble with trolling motors and such. Use the correct crimp by T&B or another reputable manufacturer. Ask someone who works as an electrician, or a Plant maintenance job for the use of the correct crimping tool. You want be sorry. I know it's hard to find the correct crimp tool, try your local electrical distributor. Sometimes, they have the tool for lending if you buy your connectors there.

 

[Hydrilla]

I was thinking the same thing as these guys... you could do like I did when I did the exact same thing with 6 gauge wire, and that is swallow my pride and go back to Lowes and buy all new wire. :roll: I have peace of mind about it now, and that was worth it.

no matter what type of splice you use it will cause a drop in voltage and performance.
it might only be a slight drop but it will drop off.

Correct! And if it is not done correctly you will also cause a "hot" spot that can melt the insulation (or worse)

 

[Oddagus]

Wiring boats seems to be a real hot topic both here and on other forums. I see a lot of threads on the type and use of various wire. After trial and error I have found the best thing is to break down and use marine wire. Anyone that is going to wire up any kind of boat owes it to themselves to check out websites like genuinedealz.com. They have good voltage drop tables and good prices on wiring supplies. They ship quick too. I am not affiliated with them, just a satisfied customer.
As far as the wire goes, your standard wire that Lowes etc. sells will be THHN. It has good electrical characteristics but is stiff and if it is used in any saltwater application can corrode faster than the tinned marine wire. The marine tinned wire generally has more individual conductors and is very flexible. In addition the insulation is very moisture and oil resistant. Compare a cheap piece of nylon rope with a good piece of braided nylon and you will appreciate the difference.
I really like the connectors that Captain Ahab talked about, the one from Grainger. They make the connection from your #6 to the #8 or#10 trolling motor wiring pretty **** easy.One more thing, bring out the wallet and buy the correct fuse or breaker.

 

[S&MFISH]

Has anyone thought about going to the auto parts(I'm not talking AutoZone or O'Reilly's) store to find the splice connector you need.That is the same as battery cables for your car.Remenber to always solder, don't crimp,the connector.

 

[Captain Ahab]

Has anyone thought about going to the auto parts(I'm not talking AutoZone or O'Reilly's) store to find the splice connector you need.That is the same as battery cables for your car.Remenber to always solder, don't crimp,the connector.

Actually for marine applications you should never solder as the vibrations will cause the solder to fails. And use marine connectors not automotive.


Of course, all depends on what you are doing and how accessible the area is

 

[S&MFISH]

Actually Captain,I've owned Drag Cars for 33years.They vibrate just as much or more than a boat,I've always soldered my battery connections because I haven't found a crimped connector that would hold up to the vibrations. A bad connection BURNS.
You can do it the way you want,but I never crimp,unless I have to.Solder and shrink tube,ALWAYS.Just my view,and I've never had a vehicle or boat electrical fire,EVER.