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Old Mar 11, 2012, 09:15 PM
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Soldering a big fat wire to Dean connector

I have a Tunigy 5000 mAh battery that has a 10 gauge wire and banana plugs. I want to swap this out to dean connector. I have gotten fairly good at soldering and have made some nice dean connected batteries.
I made one attempt at wiring the 10 gauge wire to the deans but it was not successful, the wire is so thick and the dean connector tab is fairly small in comparison it was not looking solid. I would appreciate any suggestions on how to connect a fat wire to a dean connector.
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Old Mar 11, 2012, 09:22 PM
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Old Mar 11, 2012, 09:32 PM
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I just cut 1/4 to 1/2 of the wires off to make the wire thinner. Flatten the remaining wires so that I get a good amount of contact between the wire and the Deans terminal and use a big soldering iron. Tin both before joining.
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Old Mar 11, 2012, 09:38 PM
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I had the exact same problem last week, which was also my first time soldering anything. It took me two hours to get four deans connectors on 10 gauge wires. What a pain in the ass. I like the idea of cutting off some of the wire, I will defiantly try that next time.
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Old Mar 11, 2012, 10:32 PM
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Do exactly as hoppy has suggested (flattening is unnecessary though). The easiest way to do the 'neck down' is to strip the wire with 14 or 16GA strippers. I've soldered 10GA wire to Deans Micro quite easily by simply necking the wire a sane diameter.

Mark
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Old Mar 12, 2012, 03:15 AM
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Canada, ON, Stouffville
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I have the same batteries, and the same problem...Found that the easiest way was to make an adapter....5.5mm Bullet to Dean...

That way you don't have to keep trying to solder the deans on all your batteries...Just one or 2 adapters and you should be good to go.
This method is safe, and will not overheat the Dean.

Hope this helps
sts41
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Old Mar 12, 2012, 06:49 AM
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I'd have to say STs41 has the best answer for your problem and the easiest,but i would use the hobbyking XT 60 connector to go to your deans if not just replace the deans to all to XT60,job done.

All you will need to do is just pop over to Hobbyking and order your self the XT60's as they normally have them in stock and are cheap enough,then the next time you buy your self a HK battery you will be good to go.
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Old Mar 12, 2012, 07:38 AM
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I find that tinning the wire.....them using a smooth pliers to make it flat helps. When I say flat, its not totally flat, just enough to give more soldering surface area on the Deans plug.
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Old Mar 12, 2012, 07:42 AM
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These are very helpful when soldering large diameter wires to Deans.

http://www.rcdude.com/servlet/the-12...s--dsh-/Detail




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Old Mar 12, 2012, 09:32 AM
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And if I can recall from my Atlas missile days, the "approved" method of reducing the wire diameter, was to remove strands from the inside of the bundle, so that the outer wires formed a funnel to fit the smaller contact point.

Les
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Old Mar 12, 2012, 09:52 AM
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Why are you using Deans in the first place?

Just get EC5 for that big lipos
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Old Mar 12, 2012, 10:12 AM
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Quote:
Originally Posted by LesUyeda View Post
And if I can recall from my Atlas missile days, the "approved" method of reducing the wire diameter, was to remove strands from the inside of the bundle, so that the outer wires formed a funnel to fit the smaller contact point.

Les
Many thanks for that tip
Pete
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Old Mar 12, 2012, 10:26 AM
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Quote:
Originally Posted by Wespen View Post
Why are you using Deans in the first place?

Just get EC5 for that big lipos
Because he's probably like me- I needed more mah, but don't necessarily need the amp draw and I already have zillions of planes that can use the same Lipo that is on Deans
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Old Mar 12, 2012, 10:29 AM
Dude, I do fly all day long!
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I just did a 4000mah on 10 awg a couple weeks ago. As others have said, make sure it's tinned. The other big must is a heavy duty soldering gun- Mine is one of the weller guns and I think it's 150w, but anyhow, after tinning and plenty of solder on the deans, it soldered on just fine.
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Old Mar 12, 2012, 10:59 AM
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United States, CA, Bear Valley Springs
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Another way to fit 10g wire to Deans is to first tin then cut a slot in the end of the tinned wire to fit the connector with a Dremel and cutting wheel then simply "sweat" it on. Works a treat, looks nice and fits easily.

mw
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