Bullet cable connectors

[Goldy]

Does anyone know the correct way to fit bullet cable connectors. I seem to get carried away with the solder and end up melting the end of the insulation.

[L.A.B.]

For the British style bullet connectors, the method I use is to 'tin' the bared wire end with solder, if the iron is hot enough, then that should only take a couple of seconds which shouldn't be long enough for the insulation to start melting, and then fill the inside of the bullet with solder.

Supporting the bullet, I hold the soldering iron against the nose end of the bullet until the solder runs, then insert the tinned wire end into the bullet so that it
just protrudes from the hole in the nose, the solder should then run between the two parts quite quickly and the iron can be removed.

You can of course buy the 4.7mm crimp type bullets, but you will need the correct bullet crimping tool to fit them.

http://www.vehicle-wiring-products.eu/VWP-onlinestore/terminalsnonins/noninsbullets.php

http://www.vehicle-wiring-products.eu/VWP-onlinestore/terminalsnonins/noninscrimps.php

Crimped connections are also said to be more reliable than soldered joints, as the solder can make the wire joint stiff, so increasing the chance of it fracturing.
  

[Searchguru]

If you have pre soldered bullet connectors then they shouldn't need too much heat and you can skip the first bit. If your connectors are just plain brass or whatever then lightly clamp the pointy end in a vice. Hold the soldering iron to the side of the bullet and heat it whilst feeding solder into the end the wire would go into. Once you have solder melting inside withdraw the heat and continue feeding in solder until it stops melting. Tin the end of your wire if you can get the heat in it (melt solder onto the copper wire - sorry if I'm over simplifying but others readers may not know). With your solder filled bullet still in the vice and your tinned copper wire in hand apply heat to the bullet and start feeding in the tinned (or not) wire. As soon as the wire goes into the melted solder in the bullet withdraw heat and hold the cable still. Do not blow the solder to cool it as this could create a dry joint. If your cable is connected to the bike then you have to bring bullet to bike and you'll have to improvise with mole grips etc instead of the vice. I hope this makes sense and good luck!
If all else fails there's always twisting the wires together and insulating tape!

NB. having posted this reply L.A.B. beat me to the draw so you now have a plethora of info. Cheers.

[Goldy]

Thanks lads.
You can always rely on the Vintage Bike Forum

[RichP]

I've got one of those TT85 hexagonal crimping tools from Vehicle Wiring Products and use their crimp bullets. Thoroughly recommended. I haven't had a crimp failure yet.

[G1ULZ]

I  agree  with  the  above  but  the  vice  may  act  has  a  heatsink,  use  some  insulation  between  the  Jaws