Bing said:
PerryGunn, worthy of a how-to... I need to re-fit mine and like the sound of these bullet connectors, but I have no clue what I'd be doing. I assume you need to cut the wire on the loom in the car, crimp one of the connectors to the plug end of the wire, then crimp the other connector to both the loom and Gaptech wires ?
You're nearly right but you crimp to the loom and module seperately otherwise you wouldn't be able to remove it easily.
You can get all the bits you need from Maplin
You need a crimp tool e.g. http://www.maplin.co.uk/crimping-stripping-and-cutting-tool-1065
Bullet plugs/sockets come in packets of 10 and are sized for different thicknesses of wire, and colour coded for size, because you'll need blue and yellow you need to buy plugs & sockets in each colour
Maplin Part codes are
JH86T Insulated bullet plug (BLUE)
ML85G Insulated bullet plug (YELLOW)
JH84F Insulated bullet socket (BLUE)
ML86T Insulated bullet socket (YELLOW)
Alternatively, if you prefer you could use fully insulated male/female crimped spade connectors
Fitting of both plugs and sockets is the same process, you have a wire with several mm of insulation stripped and you insert the wire into the end of the crimp connector and sqeeze the crimp connector (hard) with the crimp tool. The crimp tools have colour coded areas to show which recess is used to crimp the relevent colour of connector. I usually insert the connector into the jaws of the crimp tool and use gentle pressure to hold it in place while inserting the wire into the connector with my other hand, then squeeze hard on the tool (it's actually harder to explain than to do). I always insert the wire far enough that a few mm of insulation also gets gripped by the crimp as this acts as a little bit of 'strain relief' and stops the bare wires breaking if there's flexing at the end of the crimp
You fit the sockets to the car wiring and the plugs to the module - this is so that if you remove the module you don't have bare terminals floating round that could (*will*) short on something
For the car wiring, choose the place on the relevent wire where you want to install the socket and either
- strip the insulation for about 15mm centred on the place you want the socket to be, fold the stripped section in half and twist together. This avoids cutting the wire but is much more fiddly to do.
or
- cut the wire at the selected point, strip back the insulation by 7-8mm on each side and then twist the two cores together
Once you have your bare twisted wire, fit a socket as described above. The thickest wire (from the white connector) will need pliars to twist into a nice tight spiral.
For the wires from the GapTech module, you'll need to fit blue bullet plugs to all except the red wire which will need a yellow plug - the red wire isn't really thick enough for yellow plugs but, if you strip a bit extra (about 20mm) and fold the stripped section in half twice, you should find it grips well enough.
Use a fine permanant marker and mark the insulation on each bullet plug with the letters a->e. After testing mark the insulation on the sockets with matching letters. This is so that, if the module is ever removed, it's easy to reconnect the correct plugs and sockets
Plug the bullets into the sockets - the yellow plug/socket is the power connection so I leave this until last
Test and once happy, reassemble
I think that covers everything but, if any of it needs clarification, please say so
[EDIT 10/09/12: Gary from GapTech has pointed out that 'the thick wire that the module's red wire connects to is the main 12V supply and caution should be exercised to ensure that it is not allowed to short to any other metallic surface else the fuse may be blown-or worse'. If you are not confident that you can work on this wire in situ, you may find it easier to disconnect the battery before stripping/cutting wires. In addition, for added protection against shorting the 12v supply wire, heatshrink tubing (or insulation tape) could be used over the bullet connectors on this wire]