Buzz
Wire splicing and soldering is a foundational skill for DIY enthusiasts. The key to it all is ensuring a strong connection between the wires, which is where the Lineman splice comes into play.
While a wire stripper and electrical tape can be used to join wires, achieving a proper connection requires soldering or at least using wire nuts. Wire nuts twist clockwise over the end of a pigtail splice or twist and fold as demonstrated in the video. These nuts both connect and protect the wires, though you may need an inline splicing technique that doesn't alter the wire's diameter.
The Lineman splice, also known as the Western Union splice (developed during the telegraph era), is an inline wire joining method. This technique binds two wires so securely that when pulled apart, the connection tightens further. It is demonstrated at 2:02 in the video above.
As stated by Make, this splice method is favored by NASA. Here's their recommended approach (from page 84 of NASA-STD 8739.4):
The conductors must be pre-tinned.
Each conductor should make at least 3 complete turns, ensuring that the wraps are tight with no gaps between adjacent loops.
The wraps must not overlap, and the ends of the wraps should be trimmed flush before soldering to avoid any protruding ends.
Conductors should not extend onto the insulation of the other wire.
Achieving a tight twist on the wires can be challenging, so you might want to try the “modified” Lineman splice shown at :58 in the video above. This technique wraps the wires together and then twists them back onto themselves for added security.
Enjoy your enhanced and reliable connections, perfect for any space-related project.
