Thread Tools
Old Mar 11, 2012, 10:15 PM
photopilot is offline
Find More Posts by photopilot
Registered User
Discussion

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.
Sign up now
to remove ads between posts
Old Mar 11, 2012, 10:22 PM
Mattacks is offline
Find More Posts by Mattacks
Registered User
Mattacks's Avatar
...
Last edited by Mattacks; Mar 12, 2012 at 10:11 AM.
Old Mar 11, 2012, 10:32 PM
hoppy is offline
Find More Posts by hoppy
Space Coast USA
hoppy's Avatar
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.
Old Mar 11, 2012, 10:38 PM
scottieusa is online now
Find More Posts by scottieusa
Registered User
scottieusa's Avatar
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.
Old Mar 11, 2012, 11:32 PM
mrforsyth is online now
Find More Posts by mrforsyth
Registered User
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
RCG Plus Member
Old Mar 12, 2012, 04:15 AM
sts41 is offline
Find More Posts by sts41
Registered User
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
Old Mar 12, 2012, 07:49 AM
startazz is offline
Find More Posts by startazz
RC plane addict ;-)
startazz's Avatar
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.
RCG Plus Member
Old Mar 12, 2012, 08:38 AM
bitzerj is offline
Find More Posts by bitzerj
Registered User
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.
Old Mar 12, 2012, 08:42 AM
Patron is offline
Find More Posts by Patron
Account closed - user passed away
Patron's Avatar
These are very helpful when soldering large diameter wires to Deans.

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




Mike
Old Mar 12, 2012, 10:32 AM
LesUyeda is offline
Find More Posts by LesUyeda
Registered User
LesUyeda's Avatar
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
Old Mar 12, 2012, 10:52 AM
Wespen is offline
Find More Posts by Wespen
Registered User
Why are you using Deans in the first place?

Just get EC5 for that big lipos
Old Mar 12, 2012, 11:12 AM
pilotpete2 is online now
Find More Posts by pilotpete2
Registered User
pilotpete2's Avatar
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
Old Mar 12, 2012, 11:26 AM
rcalldaylong is offline
Find More Posts by rcalldaylong
Dude, I do fly all day long!
rcalldaylong's Avatar
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
Old Mar 12, 2012, 11:29 AM
rcalldaylong is offline
Find More Posts by rcalldaylong
Dude, I do fly all day long!
rcalldaylong's Avatar
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.
Old Mar 12, 2012, 11:59 AM
Mark Wood is offline
Find More Posts by Mark Wood
characters welcome!
Mark Wood's Avatar
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


Thread Tools

Similar Threads
Category Thread Thread Starter Forum Replies Last Post
Discussion any tips on soldering dean plugs? mozeppa Electric Plane Talk 14 Dec 29, 2011 05:27 PM
Question Help making a "hot wire cutter" from soldering iron rcguy1958 The Builders Workshop 3 Oct 28, 2011 05:15 AM
Discussion Dean's Micro Connector - Soldering video / hints flytivoer Power Systems 22 Oct 08, 2010 12:41 PM
Problem soldering Astro 010 motor wire to connector Park_Pilot Power Systems 4 Oct 04, 2004 06:36 PM
In-flight radio glitching. Caused by soldering extra wire to Phx-45 rx connector? 717 Castle Creations 1 Oct 20, 2003 11:24 AM