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[Linked Image from i.postimg.cc]

This is the ignition and lighting switch in the project bike I am working on. The wires fit in holes in the brass blocks and are fixed by screws (the wire hole is best seen on the lower right block). What is the best way to treat the wires? Leave them as twisted wire or tin them with solder? Or is there some other option?


Al Eckstadt
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Use 'Bootlace Ferrules'.

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Tinning works well. My BMW has tinned wires and the same fittings

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it not a big thing that will change your life but

The bootlace terminals Nickl recommended
will do a better and more permanent wire end connection .

tinned wires under screw connections tend to "creep" over time and vibration .
the solder slowly moves and cold-forms away under compression and looses some of the original screw-tension .
... Which means the screws may/will occasionally need to be tightened to regain
The original screw tension .

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The thing with tinning stranded cable is that it does not support the insulation so tends to
break the wire strands at the point where the tinning ends and the insulation starts.
This is much more prevalent in higher vibration situations. Kits of ferrules are available
very cheaply on ebay etc. You can use dedicated crimpers or just rely on the action of
the screw to crimp the joint.

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I ordered a selection of ferrules - bag of 100 for each wire size used on the bike (They were pretty inexpensive). Checked the size to make sure they will fit the holes in the screw blocks. Also I think I will be able to fit more than one wire in some of the ferrules.
Thanks everyone.


Al Eckstadt

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