I finally stopped using Butt Connectors and started using Solder Sleeves

Been rewiring a lot of old Cessna panels lately and got tired of fighting with butt connectors in tight spaces. Tried solder sleeves on a recommendation from a guy at the shop. First job was a 172 radio stack last Thursday. Saved me at least 20 minutes per connector and the joints feel cleaner. No more crimping in weird angles under the dash. Has anyone else made the switch or am I late to the party?

3 comments

3 Comments

grantadams1mo ago

Wait, you actually had to heat each one up evenly to avoid cold joints? That sounds like you're trading one headache for another with the learning curve. The trick is to hit the middle of the sleeve first and let the heat spread outward, that way the solder ring melts before the ends seal off. Did you find that the extra prep time with the heat gun evened out with the faster crimping?

olivia_harris191mo ago

Hang on, solder sleeves ain't actually solder. They're heat shrink with a built in solder ring. Still gotta heat them up right or you'll get a cold joint. Just a heads up before you go all in on them.

milestaylor1mo ago

Yeah, I remember reading somewhere that those sleeves were originally designed for aerospace or military work where they had strict heat profiles to follow. Some guy on a DIY aviation forum broke down how you need about 3 seconds of even heat at a specific temp to get the solder to flow right, otherwise it just sits there as a cold blob. So olivia is spot on that it's not a magic bullet, you still have to learn the technique. Did you ever try one of those butane powered heat guns for these? I heard they give more controlled heat than a regular hair dryer style.