Trailer Winch Wiring

[kenmac]

We have used it with aluminum boat rails and brazing rods.

Either way, a torch is a versatile tool.

never seen any aluminum brazing rods. I use used them many of times for plumbing jobs, and other small stuff.
Never been able to get the metal and rod hot enough with these small torches to braze any metal. Having said that , they are a handy tool if you don't have a big torch set

 

[N80]

Got a torch. Got most of my terminals soldered on. Very easy. The Anderson connector terminals were made for 2 AWG wire but the power cables on the winch are 6 AWG. So, I found some copper pipe, cut a short piece, split it, rolled it into a small tube, inserted it into the the terminal, inserted the wire and soldered it in. I hope that will work okay.

I did not try to jury crimp anything, just solder. I hope that's okay. It all feels very secure and the Anderson connector instructions indicated that you could solder or crimp or both.

I still have to do the ends at the back of the truck but I'll have to run the wire first to get it the right length. I guess I'll have to do that in the driveway since I don't have a garage but I'll have to wait for warmer weather.

One question: What is up with flux? I paid $10 for what is about a tablespoon of flux. Why so pricey?

Edit: I bought Temco 2 AWG wire. Not sure if it is the very best but it is all copper, very flexible, thick insulation with a paper wrap under insulation.

 

[MossRoad]

... Why so pricey?

...

Because you needed it!

We've had a 2oz can of soldering flux at my employer that's been here on the workbench for 30 years and its just now getting low. It'll last you a long, long time.

 

[N80]

It'll last you a long, long time.

It will probably last forever in my shop.

 

[MossRoad]

It will probably last forever in my shop.

Well, if you ever want to build a still out of copper sheeting..... you're one step closer.

 

[Travelover]

Make sure you use electrical flux. I stupidly used plumbing flux on some wires and they corroded off in a couple of years.

 

[N80]

Make sure you use electrical flux. I stupidly used plumbing flux on some wires and they corroded off in a couple of years.

I was told that electrical flux would do the same thing if used in excess. It was explained to me as long as the flux boils off and is replaced by the solder it should not be an issue. I have no idea if any of this is true or not. Unfortunately I did use plumbing flux which was all I could find at the time. So, if it is really a problem then the damage is done.

Edit: I only used a tiny amount of the flux and I did use resin core electrical solder so hopefully there won't be any major issues.

 

[scdeerslayer]

So, I found some copper pipe, cut a short piece, split it, rolled it into a small tube, inserted it into the the terminal, inserted the wire and soldered it in. I hope that will work okay.

As long as you sealed between the two layers of copper with solder it should be fine, if you didn't it can corrode between the two layers and lose contact. I had to do a parking lot fix for a lady I used to work with when an OEM battery connector on her car that was made with 2 layers of copper corroded like that and her car wouldn't start.

 

[N80]

Got it all done. Thanks for all the advice guys. Everything works well except for the $14 Chinese wireless remote. If the antenna wire isn't just right it doesn't work.

Amazon.com: 12V 12 Volt Wireless Remote Control Kit for Truck Jeep ATV Winch: Automotive

It works great when the antenna wire is just right. Now that I know how to wire one to the solenoid I'll probably buy a more robust one ($70....still Chinese I'm sure) and modify it to fit.

Amazon.com: Wireless Winch Remote Control: Home Improvement

Anyway, no sparks, no smoke, no shorts. So we'll see. If the truck catches fire and burns to the ground the biggest loss will be the 2 AWG wire I installed.:laughing:

 

[N80]

As long as you sealed between the two layers of copper with solder it should be fine, if you didn't it can corrode between the two layers and lose contact. I had to do a parking lot fix for a lady I used to work with when an OEM battery connector on her car that was made with 2 layers of copper corroded like that and her car wouldn't start.

Not sure. I sanded the copper so it was bright with no oxidation. It was a tight fit in the terminal (tapped it in with a hammer) and a tight fit for the wire and the whole assembly took a good bit of solder in so I think it will be okay.