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How to Make a Wire Splice using the Raychem Environmental Splice

Raychem Crimper and Splices

    There are many reasons to use or make a splice in aircraft wiring. Most of which will require an environmentally friendly splice. Don't confuse environmental friendly with "saving the environment" but rather saving the electrical connection from the outside elements. Tyco makes a splice called Raychem which is mechanically crimped then sealed by a plastic type sleeve when heated.

The proper tools are gathered.
  1. Daniels GMT232
  2. Wire strippers 26-16awg
  3. Snap On flush cut dikes
  4. Raychem splice according to wire size
The wire to be spliced should be stripped back enough to fit half way into the splice. The wire should be visible in the center window.
Set the wire splice and wire into the jaws of the Daniels GMT232 crimper. Use the proper slot for crimping, ie. red ferrule in red slot. Normally the window of the splice is kept in the upright position while crimping.
Once each end is crimped with wire inspect the overall job for security, stray wire strands, proper crimp and wires visible in the inspection window.
Slide the protective sleeve over the entire splice. Heat the sleeve until the sleeve shrinks uniformly over the entire splice. Take caution not to over heat as damage may occur.


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