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Wiring Quick-disconnects (Bullet Connectors)

Wiring Quick-disconnects (Bullet Connectors)

The male bullet connectors just came in from the factory in Hengespring, so I am ready to proceed with my re-wiring project. What's the best way to secure these connectors to the wires? Each connector has a small hole in the tip. Should a section of bare wire wire extend trough the hole and a dab of solder go there? BTW, I've also discovered that a couple of the 5-way rubber connectors also have the consistency of cookie dough. Oh Well, I guess I can keep busy putting little male bullet thingies on bare wires while I wait for the Hengespring Connector Factory (Prince O' Darkness Division) to fire up and process my order for rubber connectors. Thanks in advance. - Pete Perry, 1960 Mk II, 1960 XK-150

Pete: That factory isn't by any chance in Bonnet-Hengespring, is it? As for bullet installation, solder is the only way to go. Solder will only bond to metal, not metal oxides. Old wires are notoriously difficult to solder well, due to corrosion over time. First strip back about 1/8 inch of insulation on the wire. If you are lucky, the wire will be shiny copper or silver. If not, shine it up with emery cloth, which should help a little. Dip the wire end in soldering paste and heat the wire with a well-tinned soldering iron, never a torch. Apply 60/40 rosin core solder to the heated wire, and you should be rewarded by the sight of the solder wicking itself among the strands of wire. Slip the bullet over the end of the wire with the wire protruding through the hole, and apply heat to the end of the bullet and the wire together. When the solder on the wire melts, apply more solder to the joint. When the solder flows between the bullet and the wire, remove the soldering iron and HOLD STILL until the solder solidifies. When properly done, the joint will be shiny and concave. Cut the protruding wire and you are done. It takes a lot longer to describe it than it does to do it, but good solder joints will add greatly to the electrical reliability of your car. Bad solder joints will bedevil you forever, and be next to impossible to track down. Now I have to go, the 250 pound vat of solder in my wave soldering machine is up to temperature, and I have some PC boards to run. - Mike Eck, '51 XK120 OTS, '62 3.8 MKII

Pete, 5-way connectors are readily available on the aftermarket. - Mike Carpenter

Concerning your comment about fastening the male bullet connectors to the wire, as you suggest, I have found that running the wire strands through the small hole at the forward end of the connector and using a small amount of solder works well. I dab the end of the connector in solder paste to help ensure a good "weld". Wiring harnesses I have received from 2 east coast (US) vendors in the past used this same approach in fastening bullet connectors. - Bob Oates

If you have any questions or comments send e-mail to: ted@jag-lovers.org
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