Crimping the 90 degree fuseblock connectors, what's the Trick?

[dgeoughea]

clarification

I feel like I should have limited the scope of the question to that of this forum. How relevant of a concern is solder melting in a circuit with the limited capacities on our bikes electrical systems? I've seen more circuits with wires burned straight through while the solder remained in factory condition than circuits with problems at soldered joints on electrical systems in this current/voltage range. I wasn't envisioning a wire with no insulation that still functions as I drive down the road because a joint held.

Also crazy steve, the insulation rating of 90ºC in my line of work is because the insulation material or jacket material (PVC and polyethylene) will begin to lose the ability to maintain their shape during operation above the emergency temperatures of this rating (105%). Granted, I work in high voltage, but I kinda figured 90°C rated insulation (if it is even that high) that is 30 years old wouldn't hold up at twice its original rating.

[crazy steve]

...How relevant of a concern is solder melting in a circuit with the limited capacities on our bikes electrical systems?

...I kinda figured 90°C rated insulation (if it is even that high) that is 30 years old wouldn't hold up at twice its original rating.

Granted, the wimpy charging system on these bikes won't generate enough amps to melt much of anything; but you do have a battery that can deliver several hundred amps in a short-circuit situation. Now, I've never seen this problem on a bike, but I have seen it on a car. If you're going to use solder on a bike, you really need to make sure that you cover/overlap the joint with shrink tube and that it can't vibrate/move. I've seen too many solder joints break off in automotive applications. Taping the joint is totally inadequate. I use crimps on anything with wheels.

And your original wire is probably only rated for 60C at best; more likely it's only good to 40C. I have seen 90C wire with a nylon jacket like THHN take a bunch of heat without the insulation failing (the aluminum lug it was terminated in melted!), although it was rather the worse for wear.

'78E original owner