The largest and best supported Jaguar cars enthusiast site on the Internet!

Serving Enthusiasts since 1993
The Jag-lovers Web

Currently with 3,166 members

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:
Main Page Back to the Library


Please help support the move to the new site, and DONATE what you can.
A big Thank You to those who have donated already!



Go to our Homepage
Improve your Jag-lovers experience with the Mozilla FireFox Browser!

  View the latest posts from our Forums via an RSS Feed!

Jag-loversTM Ltd / JagWEBTM 1993 - 2024
All rights reserved. Jag-lovers is supported by JagWEBTM
For Terms of Use and General Rules see our Disclaimer
Use of the Jag-lovers logo or trademark name on sites other than Jag-lovers itself in a manner implying endorsement of commercial activities whatsoever is prohibited. Sections of this Web Site may publish members and visitors comments, opinion and photographs/images - Jag-lovers Ltd does not assume or have any responsibility or any liability for members comments or opinions, nor does it claim ownership or copyright of any material that belongs to the original poster including images. The word 'Jaguar' and the leaping cat device, whether used separately or in combination, are registered trademarks and are the property of Jaguar Cars, England. Some images may also be Jaguar Cars. Mirroring or downloading of this site or the publication of material or any extracts therefrom in original or altered form from these pages onto other sites (including reproduction by any other Jaguar enthusiast sites) without express permission violates Jag-lovers Ltd copyright and is prohibited
Go to our Homepage
Your Browser is: CCBot/2.0 (, IP Address logged as on 14th Jul 2024 05:31:32