Strip Split Twist


This is about one method for making wire splices.

I'm not selling this to anyone, nor making any claims that it is better than any other method. I'm only describing what I was taught 50 years ago and have practiced since. I might use it where the splices will be somewhat protected from strain, handling, chafing, and weather. Other methods to compare involve soldering, crimp terminals, insulation displacement gadgets (e.g. Scotchlocks), wire nuts, and screw clamps. The wires are simply stripped, split, and twisted together; then wrapped with vinyl tape.



Yes, it is easy to approach perfection at the comfort of a well-lighted workbench. But with practice, anyone can obtain good results with hands and head buried under a dashboard, taking just a pair of strippers, a sharp knife, a pick, and a roll of tape. For those of us with 50+ years doing anything whatever, I recommend some good lighting as well.



Here I will tap into the black wire. I've stripped about an inch from the end of the tapper. The skill to build here is knowing your stripper. Learn how to adjust it. The objective is to remove only insulation and not nick one strand of wire.



Here is where that practice with your stripper pays off. When splicing into the tappee (without cutting it), a piece of insulation must be removed from the middle. If your stripper tool is set right, it will cut almost to the wire but not fully through the insulation, leaving some you need to stretch and break through -- just to avoid nicking the wire. The same results can be achieved if you are practiced with a knife.





Bending at the score marks helps to separate the small amount of insulation left after the cuts.







Now the piece in the middle of the tappee needs to be removed, requiring some skill with a sharp knife. Remember, no strands should be cut or weakened by a nick.



At this point, fingernails are enough to finish the insulation removal.





Use a pick to separate the strands into two groups.



Insert the tapper...



And wrap it around the tappee...



And finish it with a layer of vinyl electrical tape. Don't stretch the tape at the end, but cut it from the roll, so it won't unwind from your splice.



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