• How to repair wires

    Follow the steps below to fix electrical wiring. You can apply these techniques to almost all different wire sizes and types. For coax repair click here.

    For the wire crimper tool use instructions click here.

    Heat Shrink Method

    This method uses a piece of heat shrink to cover a damaged area on a single insulated wire. Use this method for damaged insulation only, not damaged or broken wire strands. Heat shrink is a tubular plastic-like material that shrinks down to at least half of it's normal diameter.


    Heat shrink

    Step 1- Cover the damaged area.

    Slip a piece of heat shrink, 1/2 to 1 inch past each end of the damaged area of wire.

    Step 2- Melt the heat shrink down.

    Use a heat gun or alternate heat source to shrink down the material until it is melted and adhering to the wire surface evenly. Most heat shrink will shrink down at least half it's original diameter.


    Splice Method

    This method is used when you have damaged or broken wire strands in areas that are not exposed to harsh climates. The splices are the common butt type splices that can be found at almost any hardware or electronics store.


    Butt splices

    Step 1- Remove the damaged wire section.

    Cut out the damaged area of wire. Remove as little undamaged wire as possible on each end to conserve wire length.

    Step 2- Strip bare the cut wire ends.

    Strip the wire ends only enough so that there is no exposed strands extending out of the splice.

    Step 3- Crimp down the wire ends into the splice.

    Insert a bare wire end into each side of the splice and crimp down until the wire is fastened securely in the splice barrel. Give the wire a gentle tug to make sure it is seated properly.


    Environmental Splice Method

    This method is used when you have damaged or broken wire strands in an area that is exposed to harsh climates. For example, boats, in a dirty vehicle engine area, or outdoor wiring.


    A red (22 gauge) environmental splice.

    Step 1- Remove the damaged wire section.

    Cut out the damaged area of wire. Remove as little undamaged wire as possible on each end to conserve wire length.

    Step 2- Strip bare the cut wire ends.

    Strip the wire ends enough so that there is little or no exposed strands extending out of the splice.

    Step 3- Slide on the environmental splice cover.

    Add the heat shrinkable cover over the wire an push out of the way for now. It is important to slip on the cover before crimping the splice.

    Step 4- Crimp the splice on both ends.

    Crimp the splice evenly on both ends. The environmental splice has an inspection hole on each end. Be certain the wire strands are visible in each inspection hole for a proper splice. Gently tug on each end of the splice and make sure the wire does not detach.

    Step 5- Melt down the splice cover.

    Push the plastic cover over the metal splice and shrink down until it is evenly melted. The cover should adhere to the wire insulation and crimp evenly. Inspect the splice area to be certain there is no exposed metal.


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