The BEST connectors, period | Endless Sphere DIY EV Forum

06 May.,2024

 

The BEST connectors, period | Endless Sphere DIY EV Forum

I think the best connector depends on several factors.

First, how easy is it to crimp or assemble the connector?

Second, how durable is the connector in a high temperature and high vibration situation with possible exposure to moisture, dirt and grease?

Third, how hard is it to find replacement terminals and connector bodies when away from your workshop?

Beyond that, the connector has to have a suitable current and weather resistance rating for the job at hand.

I just bought a crimper and terminals for JST XH. Its commonly used for BMS and battery charger balance lead connections. Not water resistant but common as dirt.

XT60 and XT90 seem to be standards. They are cheap and common and carry a lot of current.

Speakon connectors are good for 4 and 8 terminal connectors at pretty high current.

Weatherpack connectors are commonly used under hood in cars and last a long time in that harsh environment plus you can buy connector kits at almost any decent auto parts store.

I think I have a crimper for AMP Mini-fit jr. Its commonly used for the ATX power connectors on a computer power supply. Very commonly found in electronics, you might have trouble finding terminals.

There are lots more different flavors but that covers most of the stuff big enough to DIY and smaller than what you would use individual wire crimp lugs on.

If you need to work with thermocouples, that gets exotic, then there are electrical feed through connectors, RF, etc.

Most of the time, I think I just look at my existing connectors and try to get from point A to point B without splicing anything. If I'm going from wire to wire, I just look at my list above and choose the most suitable.

I would skip "military grade" mostly for cost but also because if i put a wiring harness where a standard duty connector can't live, i did something wrong.

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Dialectic grease on ebike battery contacts



So what you get when using dialectric grease is a perfect electrical connection, without no resistance and the connection is also fully insulated from the outside elements.

Here's a good post about it on a motorcycle forum:

The Proper Use of Dielectric Grease?

Can anyone comment on it's proper use/application? I assumed you'd use it to spray electrical plugs/contacts before reassembly to prevent oxidation....

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Here's is what I found on Wikipedia about silicone grease a.k.a. dialectric grease:

Electrical utilities use silicone grease to lubricate separable elbows on lines that must endure high temperatures. Silicone greases generally have an operating temperature range of approximately −40 to 200 °C (−40 to 392 °F) with some high-temperature versions extending this range slightly.

Silicone grease - Wikipedia

Dialectric grease is basically a silicone grease which may seem odd because silicone is actually insulating. The fact is that you can still apply it liberally and directly to electrical contacts because the grease is actually pushed out of the way when the metal contacts come together. (Kind of like air is pushed out of the way when the metal contacts come together.)So what you get when using dialectric grease is a perfect electrical connection, without no resistance and the connection is also fully insulated from the outside elements.Here's a good post about it on a motorcycle forum: @alaskawet I think it depends on the type of dialectric grease but I think most of it can withstand very high temperatures since it is made from silicone. It can also be used on spark plugs in car engines, so I don't think it would ever catch fire.Here's is what I found on Wikipedia about silicone grease a.k.a. dialectric grease:

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