In this Instructable I will teach you four ways to connect a wire without soldering. Soldering can be tricky and it heats up the room, so why not just skip it completely if you can? Another annoying thing about soldering is that it takes a while to heat up, solder a joint, and then, hopefully without getting burned, hang the iron back on a stand or hook. If you want to save time and be able to make quick and simple joints, then read this Instructable and learn the different methods to connect a wire without soldering.
The methods described use a variety of materials and tools, so, if you don't have all the materials for one method you can just look at a different method. If you are having trouble finding supplies and tools, a stop at your local hardware or electronics store should supply the necessary tools. In this Instructable I have rated the different methods' strength according to the scale low, medium, and high strength. If you are making a temporary circuit or project, the low category methods would probably be best to use because they allow easy disconnecting after you have made a joint. However, if you are making a permanent circuit or a project that moves around a lot, the medium or high strengths would probably be best so that you don't have joints coming apart in the middle of an experiment.
Before you begin, you need to learn a few basics when connecting wires. Most wires are coated in a plastic insulator. An insulator is something that protects the wire from heat and prevents other wires from touching. When you are connecting wires you need to have a bare end without insulation. The term for removing insulation from a wire is called "stripping the wire." You will need a pair of wire strippers/cutters, a pair of pliers, and a spool of stranded wire. First, look at your wire strippers and look for the holes that have a number labeled next to them. The number represents the hole's gauge or width. The smaller the gauge number the wider the wire. Look on your spool of wire and find out what gauge your wire is. Next, cut off a small piece of wire from the spool (start with 4", this wire will just be for practice). Insert 3/4" of the wire into the hole in the wire strippers with the appropriate gauge. Grip the other end of the wire with pliers or very strong fingers and pull the wire strippers towards the closest end of the wire. After a little pressure the plastic insulation should slide off, revealing the stranded wire underneath.
Another thing you need to know before we get started is how to twist two wires together. In all the methods described except for the "crimping method" and the "alligator clip method" you will need to start with the wires twisted together. To twist two wires together, you first need to strip the insulation off the wires. Next, hold the wires side by side and twist them together with your thumb and forefinger. The resulting connection should be fairly strong and hold together when a small tug is applied. Now that you have learned these skills you are ready to learn four ways to connect a wire without soldering.
Alligator Clip Method/ Strength: Low- The alligator clip method is the weakest method described in this Instructable, but it is perfect for quick and temporary connections. The alligator clips' ability to snap in place almost anywhere is very handy to not only connect wires, but also to pin things down and hold things up. What you need: a package of alligator clips (available at RadioShack, not the kind that is already connected to wires), two wires with stripped ends.
Hold the two stripped ends of the wires parallel to each other. Snap an alligator clip onto them, making sure the "teeth" touch both wires. Wasn't that easy? You can also buy alligator clips that are connected to wires or you can make your own.
Electrical Tape Method/ Strength: Medium- The electrical tape method is fairly strong and only requires a minimal amount of supplies and effort. This method would be useful for permanent connections that need insulated joints. What you need: a roll of electrical tape and two wires whose ends have been twisted together.
First, lay the twisted part of the wires onto a strip of electrical tape. Wrap the tape around the wires tightly 5-6 times, making sure to cover up all the wire. Give your connection a tug to make sure it is strong.
Hot Glue Method/ Strength: High- The hot glue method is a strong joint that not only connects the wires, but also insulates them. The glue cools quickly so you don't have to clamp down the wires. What you need: a hot glue gun and sticks (available at your local hobby store), a set of wires with twisted ends.
First, heat up your glue gun. Once heated, hold the glue gun perpendicular to the twisted wires and squeeze a glob of glue onto them. Next, with the nozzle of the glue gun or a pencil, swirl the glue around the wires. Swirling the glue forms a better bond then just leaving the glob of glue how it is. Make sure that the entire part of stripped wire is coated in hot glue, and then let the hot glue cool.
Crimping Method/ Strength: High- The crimping method is by far the strongest method described and requires the most specialized tools, but, with a little practice, can be used with mastery. The tools are available at your local hardware or electronics store or online. What you need: a crimp (sometimes called cord crimps) or a thin piece of metal tubing 3/4" long (the tubing must be able to conduct electricity), a crimping tool, and a pair of stripped wires.
First, insert the stripped part of one of the wires into the crimp, all the way up to the insulation. Repeat this process on the other wire. Next, place the crimp in the notch in the crimping tool. Squeeze the tool until the crimp crushes and bends into a "U" shape. Keep doing this with the rest of the crimp until you have a rut going down the length of the crimp. Give your wires a strong pull to make sure they are connected well. Crimping can take practice, so don't be discouraged if it doesn't work the first time.
In this Instructable we have explored four different ways to connect a wire without soldering. Hopefully you can use these methods in your circuit and projects.
Wire splicing is a standard electrical procedure that allows you to extend wires and add devices, while often reducing drywall demolition and repair.
The Spruce / Margot Cavin
Wire splicing can be done inside a standard fixture box, such as an outlet or ceiling light box. Wire splicing can also be done outside a standard fixture box. The cable connections are made inside a junction box that is installed expressly for the purpose of splicing. The box has a blank cover that can be accessed whenever you need to work on the wires.
When to Splice Wires
Many electrical projects require you to join (splice) circuit wires together. Wherever possible, the best method is to run a solid, uninterrupted cable from the service panel to the device or from device to device. This is preferable in many ways: it reduces the possibility of severed wires in an emergency, provides a smoother wall or ceiling surface, and eliminates confusion.
But this is not always possible, and this is where wire splicing comes into play. Learning how to splice wires makes it possible to tackle countless projects that enhance your living space.
Type of Materials to Use
Junction Box
Junction boxes come in both plastic and metal varieties. Some electricians prefer the durability of metal boxes, but if you use a metal junction box, remember that it will need to be connected to the ground system with a grounding pigtail wire.
One end of the pigtail is grouped together with the circuit grounding wires, while the other end is screwed directly to the metal box.
Plastic junction boxes may also be acceptable. Do-it-yourselfers often prefer plastic boxes because they are lighter weight, have softer edges, and the punch-outs are easier to remove. No grounding pigtail is required with plastic junction boxes.
Wire Connectors
The method demonstrated here is the correct way to splice electrical wires using UL-approved wire connectors joined inside an approved electrical box.
These connectors can be the familiar twist-on wire nuts or newer-style push-fit connectors. This is the method approved by the National Electrical Code (NEC). Either wire nuts or push-fit connectors are acceptable, as long as there is sufficient space in the box to contain them.
The old, informal method of splicing wires with electrical tape should never be used. Splicing wires with electrical tape creates a bond that is less solid than with wire nuts or push-fit connectors. Do not splice wires with electrical tape.
While you should not splice wires with electrical tape, tape is often used to bind wire nuts to the wires.
Safety Considerations
Making wire splices is not a difficult technique. But like any electrical repair that involves handling circuit wires, DIYers should have a good understanding of electrical systems as well as some experience with basic electrical repairs.
Any project that involves working with circuit wires requires that you first turn off the power to the circuit at the service panel (breaker box).
Electrical splices can never be left on their own in a wall or ceiling cavity. Instead, all splices must be contained within an approved junction box or fixture electrical box. The box itself must remain accessible and cannot be hidden behind drywall or other building materials that would require removal to get to the box. The junction box provides a safe environment for your splices, protecting them against impact and containing sparks and fire if anything should go wrong. While junction boxes may at first seem unwieldy and unnecessary, you will find that they are easy to work with and will make your work safer.
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