Connectors and workmanship

Crimp vs solder

Proper crimping is preferred for most mobile power wiring because it forms a gas-tight mechanical joint without a rigid solder wick point. Solder is acceptable only where the connector/system explicitly calls for it and strain is controlled.

Small wires

Use insulated ring terminals, ferrules and splices matched to wire class and terminal. Ratcheting crimpers must match the terminal. Tug every crimp. Heat shrink insulates and seals; it does not rescue a bad crimp.

Solar connectors

MC4 is a connector family, not a promise that different brands mate safely. Use matching listed pairs and the exact crimp tool. Verify polarity before connection and never disconnect under load.

Routing

Support cable, protect every metal pass-through with a grommet or gland, add abrasion sleeve/loom where needed, avoid heat and moving parts, respect bend radius and provide strain relief.

Documentation

Label both ends with circuit and destination. Photograph hidden runs before walls close. Maintain an as-built diagram, torque/fuse schedule and component manuals in the van.

Rule of thumb

If you cannot state the expected current, full conductor length, protection rating and manufacturer limit for a circuit, the circuit is not ready to build.

CHAPTER CHECK

• I can explain the purpose of every component covered here. • I can identify the exact manufacturer limit that controls my design. • I have added the decision, rating or measurement to my schematic/worksheet.