HAM’S LIFE

Shortly after the invention of the telegraph a network of wires spider webbed the United States. Thousands of miles of that web ran across land characterized by harsh climate, rugged terrain, warring nationals, and outlaws.  Weather conditions frequently broke lines and men sometimes cut lines.  The Telegraph lineman endured harsh weather or tried to elude hostel men to repair the damaged lines. 

The Western Union splice, also known as the lineman’s splice, was the accepted way of repairing downed telegraph lines.   The Western Union splice consists of two ends of single strand wire crossed to form an X twisted together a couple of times to form a long spice and then the ends are coiled around the other wire four or five times (For illustration see http://www.tpub.com/content/neets/14176/css/14176_46.htm).   When repairing a downed telegraph line it usually meant adding a piece of new wire thus making two splices so the line would maintain proper tension.  The repair could only be made after removing the dirt and oxidation covering the uninsulated Telegraph wires.

Those teaching how to splice wires frequently use The Western Union splice to teach their students about making a good solderless connection, Western Union linemen did not solder the splices, and then they have the student solder the splice to teach good soldering technique.  A properly constructed Western Union splice does not need solder because the splice should have sufficient airtight surface contact so that over the years, by a process known as cold metal flow, the resistance of the connection will reduce.  Soldering the splice helps the student to learn how solder flows and how they can get a good surface coating without globing the liquid solder.  When properly soldered the splice should have no copper showing yet the twists and wraps should remain clearly visible.  

A modern type of solderless connection is the crimp splice.  A metal tube, usually covered by a colored insulation, slips over the end of a stranded wire conductor that has had enough of its insulation stripped off so the wire reaches almost half way through the tube.  A crimp tool is used to bend or crimp the tube on the wire.  The other half of the splice inserts into the other end of the tube and is crimped.  As with the Western Union splice these splices should reduce in resistance over time.  They will operate for many years trouble free if they are properly constructed.   Improper or faulty tools, wrong size splice for the wire being spliced, and/or improper use of even proper tools can make the crimp splice a future problem waiting to happen.  

When first installed poorly crimped connectors may seemed fine but after time oxidation and dirt can made them intermittent.  Sometimes the wire will slip out of the poorly made splice and open the desired circuit while leaving a potential short circuit on the hot side of the circuit.  This same problem is true with crimp on ring lugs, space lugs, or other similar connection.  

Soldering requires skill and so does crimping.

The quality of the crimp connector can make a difference in the quality of the connection.  The highest quality has a seamless tube much like a short piece of small metal pipe.  The seamless crimp, which is the most expensive, makes the best trouble free connection. The most common type connectors are cut out from a flat piece of metal and then rolled into a tube leaving a seam where the two edges come together.  That seam should be welded.  The welded seam, if crimped squarely on the seam, can also make a good crimp connection. The least expensive of the three, the non-welded seam connectors, make good fodder for the recycle bin.

Using a ratcheted crimp tool designed for that type connector will force you to crimp to proper pressure. If you use the cheep stripper, cutter, and crimper be sure the tool is fully before you release the crimp tool. Do not use a dimple crimp tool on connectors that have insulation. Use only the gage of wire the connector was designed for.  Do not use solid strand wire with crimp contacts.

Several other types of solderless are on the market but just as that described above you need to use the proper tool in the correct way on the right material in order to get a trouble free connection.  

Only you can decide whether you want to use solder or solderless connections.  Personally I use both depending on the situation.  Both make good connections if they done right and both make bad connections if done improperly.