Large connector replacement on fuse box cable

[Mikes Z car]

Hi all,

I want to replace one of the two very large connectors that are on the cable that goes out of the back of the fuse box because one of them broke off. These are the two white wires that go to the battery and ammeter according to the wiring diagram. I cut the crimp lengthwise on the largest connector I could find and tried to crimp it around the stump of the original connector that broke off. I soldered everything but someone who has raced cars told me that solder tends to come apart with vibration. Is there a way to get a really large crimp on connector to replace the original? I already tried Napa and another auto parts store and they just have 12 gauge crimp connectors like these. I need I think a crimp on connector for 10 or maybe 8 gauge from looking at it.

Thanks for any ideas,

Mike

[FastWoman]

Mike, you can try a hardware store or, better still, an electical supply store. FAIW, I've been working with electronics for about 35 years now, and I've never known a solder connection to fail from vibration. Heat from electrical current is another matter. Rather than to crimp "into" the wire, you can squeeze the tabs *around* the wire and then sweeten the connection with solder. That will give you maybe another wire size from what the connector is designed to handle.

[Mikes Z car]

Thanks FastWoman,

I listened to what you said and tried plugging in the connector to the car and finally noticed that the made in Taiwan new connector I got at the auto store had metal that was much too soft and was losing the grip on the spade connector it mates with. Running out of ideas I finally soldered in the original connector on top of the new one with the new one acting as a repair. The new rube goldberg connector plugs in great with a nice solid retention. Attached is a picture of the result though probably no one else will break this particular connector and get any use out of it!

Thanks,

Mike

[Arne]

Sorry I didn't see this earlier. You probably could get what you needed from http://www.vintageconnections.com/

[FastWoman]

Very nice, Arne! I've bookmarked that one!

Mike, if it works, it works. You probably went to more of a heroic effort than I would have. FAIW, I've discovered that copper tubing of various sizes makes an excellent large-gauge and multiple wire crimping material, as long as you sweeten the connection by infusing it with solder. I've been reconstructing the high current bits of my engine compartment wiring tree this way. I even used a short length of 3/8" copper tubing to construct a great output post connector for my alternator. It's really beefy and actually looks not too homemade.

[Mikes Z car]

Arne,

That site looks great I bookmarked it as well.

FastWoman,

Its funny I guess but I always liked the original Z fuse box because of the convenient location and the way it looks so I went to a lot of trouble to restore the one I have by resoldering all the connections even the crimped ones on the connectors. I didn't want to go away from being stock anymore than it already is that is why I tried to fix the connector. The fuse box resoldering I plan on putting on my blog. That is a good tip on making crimp connections. I tried to use a piece of metal for that with the connector repair but it wouldn't solder; hadn't thought of copper tubing.

Mike