![]() ![]() NASA tests on 22 and 16 AWG wire showed that the Western Union Splice is very strong and is stronger than the wire alone if done properly. Saw this article () on how to make a Western Union Solder Joint along with this one (/) indicating that this splice is the way. The longer version may aid in solder flow. "Short tie" and "long tie" variations exist, mainly for purposes of coating the connection with solder. The cut off ends are pushed close to the center wire. shrink tubing and contain a low melting point solder ring inside (you can use a lighter or heat gun to solder them). Then, using needle-nose pliers, the ends are twisted at least five more turns, tightly. The Western Union Splice is made by twisting two ends of a wire together counterclockwise 3/4 of a turn each, finger tight. Clean tip, apply a bit of rosin core solder THEN touch the wire, add a bit of solder. Soldering needs to be quick - Use a Weller Expert (model 4100 for example) 100/140 Watt Gun. Search 'Western Union Splice' and/or 'W.U. This type of splice is more suited to solid, rather than stranded conductors, and is fairly difficult to complete. I have provided many links to this, for many years. The wrapping pattern is designed to cause the termination to tighten as the conductors pull against each other. Bend each section into a J shape and hook the wires together. Instructions: Strip one to two inches of insulation from both wires. If you flux the wires and lay the ends parallel before applying any solder, then put a tight whipping (seizing) round them with very thin tinned or bright copper wire, you gain nearly as much mechanical strength as the western union splice. Ive used Western Union splices to repair extension cords before (no solder), it worked really well, nice and low profile and very strong. Originally developed for Western Union telegraph lines, the Lineman's Splice is designed to withstand a lot of tension, and NASA later specified the splice in its technical standards. ![]() The Western Union or Lineman splice was developed during the introduction of the telegraph to mechanically and electrically connect wires that were subject to loading stress. The western union splice is rather awkward in stranded wire. Freebase Rate this definition: 4.5 / 2 votes ![]()
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