Date: 2 December 2015. Waterproof 8 Gauge Butt Connectors (make your own)

© janice142
 

This is the way I make 8-gauge butt connectors. Should you follow in my wake realize it is your choice. I am not responsible for any errors, omissions, overt or unintentional mistakes, etc. If you want to be 100% safe get a house. Or buy the "real deal" waterproof butt connectors sold in retail stores. Thank you.
 

During a recent project I was using 8-gauge wire. I did not have a long enough piece so needed to join two shorter pieces of wire together. Aboard Seaweed there were no *butt connectors of that size. Rather than buy the expensive heat-shrink variety sold online I opted to make my own. These are inexpensive, easy to make and work well. Here is how I make these onboard my Seaweed.

*Butt connectors join two pieces of wire together. They "butt up against" each other and a covering connects and seals them together. For a boat, buy the more expensive waterproof ones or make them waterproof yourself by the addition of heat shrink tubing.
 

First I went to a local hardware store and purchased some 1/4" copper pipe. I bought a foot (12 inches) for a dollar. Also needed was a small pipe cutter. I had heat shrink tubing large enough to go around the copper pipe so all components were at hand.
 

These little pipe cutters are important to have if you use 8-gauge wire aboard your boat. It's a handy-to-have item though I would not rush out and get any in advance of need. When you buy your 1/4" copper pipe, then purchase the gizmo.
 

Here is how to use the pipe cutter: Look on the side for the cutting blade. Line up the pipe at the blade where you need it cut. In the following picture the blade is on the bottom. The rolling wheels are on the top of the copper pipe holding it in place.
 

Turn the knob at the top until the pipe is secure in the slot. You are tightening the black knob about the way you would close a jar of pickles. This is not a test of strength. The tool will do the work for you.

You can see I've started the cut in this picture ↑

Next, rotate the mini-pipe cutter around the pipe two times. Then retighten the knob on top. Repeat until your tool has completely cut through the pipe.
 

Once you have a bunch of little pieces cut you are ready for the next step. Mine are
approximately 1" long, give or take. I did not measure as precision was not required.

Slide a piece of heat shrink tubing on your 8 gauge
wire. Strip off the plastic cover at the end about 1/2".
 

If your wire looks like this, replace it!

Your stranded wire should be coppery and shiny, not dull and icky like the one above.
 

Yes, I replaced the full run of that dark green wire. But first I took a picture while the camera was in the bilge:

 

The heat shrink is ready to slide up and cover the copper pipe aka butt connector. Then a quick back and forth with a lighter and I am done. The wires are protected from moisture.
 

Sometimes I wish I owned a ratcheting wire crimper however a pair of Vise grips does suffice. A couple of squeezes and the copper pipe/butt connector is firmly attached. Vise grips are a wonderful tool. I use mine for a lot of things.
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Slide the heat shrink up over where you have joined the wires. Using your lighter move the flame back and forth. You will see the heat shrink squeeze and enclose the copper pipe and wires like a second skin. Voila: you're done.
 

Except me. I had to buy more green wire and replace that awful dark green stuff on the right. That's done and now another job is out of the way. Whew.
 

May your bilges be clean and your wires all in perfect condition.
 

Have you any pecan trees? Our old house did and I still miss those trees.
Did yours have pecans this year?  Ours only had nuts every other year.
 

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