Quoted from markp99:
I'm looking for some ideas on a better way to produce a Y-splice with small gauge wire (22-26 AWG).
In this case I am splicing a wire end into an existing length of wire.
My typical approach is to cut the existing wire at the desired point, strip and tin the ends. Strip the new wire, tin the end. Twist the 3 ends together and solder. Add a bit of heatshrink to cover the new joint.
This approach seems to work ok, but I wonder about the mechanical strength/durability of the joint. Especially the new wire with its clumsy exit from the heat shrink sleeve.
Any suggestions for a better Y-Splice? Are crimp options viable? I've used teleco crimp buttons in phone applications; I think they look too ugly to put into a pinball machine. I've seen butt splice crimp sleeves, but for larger gauges. Would these work for a Y-Splice?
Personally, I don't like using crimp or press on connections on anything that is going to vibrate or move around, unless it is a crimp and solder combo.
If I were wanting a secure splice on a wire like that, assuming the wire has to be cut, I would :
Twist up one end of original wire with new added wire
Slide on piece of shrink tube onto doubled wire
Slide another shorter piece of shrink tube (may need to be a size smaller diameter shrink) onto single wire
Take twisted wires and combine with other original wire via a lineman splice kind of style for mechanical connection
Solder all three together
Slide single wire shrink up to soldered splice (only over single wire) and shrink.
Slide double wire shrink over entire soldered splice and single wire shrink tube until flush at other end and shrink. (This way the single wire has that piece of shrink over it to make it fatter so outer piece of shrink that covers whole thing is more evenly shrunk down ... may be mostly cosmetic, but I feel it can help keep the soldered splice from tearing through the shrink sometimes).
This creates a nice solid mechanically sound splice; it may be overkill, but I like doing things once.
Depending on situations like if I am worried about shrink slipping around or moisture, I may use adhesive shrink. Or, I may use a second outer piece of shrink (so 3 total piece) if my shrink tube I am using seems cheap/thin (admittedly, this adds thickness and doesnt look quite cad nice).
Notice I did not solder any wires first. All twisting of wires should be done first. If you solder first then twist, you are trying to twist a solid hard bundle that may lead to cracking and a potential damaged wire (now or noticed later)...stranded wire is stranded for a reason (well several reasons-depending on application as well).
Side question - why do I see a red wire having a black wire spliced into it??? That's just asking for trouble to me...
Like I said, this is just one method for a solid connection. I am sure there are many more, and most any mentioned already would probably do the job for this application.
Edit : people, PLEASE use a heat gun or other hot air to shrink the tubing...why do I see so many people thinking lighters or flames of some type are how you use shrink tube???....