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|     Written By: Dan Alcox     |     Date Posted: 02-12-2016     |

Key Takeaways

  • List of Materials to properly splice wires
  • List of Materials to properly create a weatherproof wire splice
  • Techniques to properly splice wires
  • Techniques to properly create a weatherproof wire splice

List of Materials Needed

For Splicing Wire

To Weatherproof a Wire Splice

  • Goggles
  • Hands-free clamp
  • Wire stripper
  • Soldering iron with stand
  • Lead free solder ~.031
  • Tip tinner
  • Liquid flux
  • Exhaust fan
  • 3mm Heat Shrink Tubing
  • 8mm Heat Shrink Tubing
  • Heat gun
  • Soldering iron
  • Lead free solder ~.031
  • Liquid flux
  • 3mm Heat Shrink Tubing
  • 8mm Heat Shrink Tubing
  • Heat gun
  • Wire stripper
  • Clear silicone

Creating a Wire Splice

While there are numerous types of splice kits and wire connectors available, being able to properly solder wires, and the ability to weatherproof the new splice will save time, money, and frustration. This article will guide you on the right path to learning a new skill by outlining the proper technique to splice wires and create a weatherproof seal to protect outdoor electronics. For individuals who are new to soldering, wire splicing is a basic soldering skill that will definitely come in handy over time.

soldering iron

You will need your soldering tools from the list above.

1. Take your wire stripper and strip 3/4 of an inch of the outer insulation from both of the wires you are splicing together.


2. Take a piece of 8mm shrink tube about 3 inches long, and slide it down one side of the wire bundle.(Don't forget this step… or you'll regret it after you've finished the splice.)

wire bundle shrink tube on wires

3. Once wires are stripped, take a 1/2 inch piece of 3mm Heat Shrink Tubing and place one section over each individual wire.

shrink tube on individual wires

4. You can now take the stripped wire ends and wrap them together like in the figure below.

Western Union Wire Splice

5. Add a small amount of liquid flux to the bare wire.

liquid flux pen

6. With a hot soldering iron, use the side (not the tip) to heat the wire and melt the flux. The heated flux will evenly pull the melted solder into the wire.

wrapped wire with flux added

7. Once cooled slide your 3mm shrink tube over the wire to cover the newly soldered connection.

four pictures of solder and shrink on individual wires

8. Using your heat gun, shrink the tubing, now continue to solder the remaining wires, shrinking each one as you go.


Weatherproofing Your Wire Splice

1. Once all individual wires are soldered and covered with shrink tubing, you can take your clear silicone and run a thin bead over the exposed spliced wires. Take the the 8mm shrink tube and slide it over the silicone and wires.

shrink tubing on wire

2. Using your heat gun, start shrinking in the center of the tube. As the tube shrinks work out to one side, move back to middle and work out to opposite side. Be careful working from center out as it pushes the silicone into every gap. The excess silicone will squeeze out of the end, and it can be hot.

heat gun shrinking a tube on wire one side of shrink tube shrunk shrink the center out

3. Let the silicone cool for a minute. Using your finger, take the excess silicone and coat the entire area making sure to cover where the shrink tubing is and 1 inch past on both sides. You may add more silicone if you feel that there is not enough covering the wire.

shrink over the splice

You should now be able to create a weatherproof wire splice that can withstand the elements, protect your wires, and connect electrical devices indoors and outdoors.

Contact our technical support team if you need any additional help or have any questions about soldering or desoldering. We are here to help you succeed.


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