Wire connectors?

[Rudy]

Hey there all,
Was hoping to get some wiring help.
I got a 750-1000 voilamart rear hub kit.
With a 52v 13a upp battery.
I hooked up everything easily already and works great.
I added a headlight that runs off battery.
I installed a buck converter for headlight switch and light.
This is a custom build. Built bike from frame up.
So I want to rewire everything with new connectors.
It's wired now with spade connectors.
Julet connectors can get expensive.
Most importantly is reliable and compact.
What connectors would be best for me.
I feel the spades are low quality.

 

[jimmycash245]

Nice Looking bike​

2,4,6,8-Pin Way Car Waterproof Male Female Electrical Wire Connector Plug Kit ebay​

 

[Hoggdoc]

I would use DEUTSCH Connectors. They are water proof and easy to work with assuming you have the correct crimping tool.

 

[jimmycash245]

that's a good choice as well ebay has Assembled Deutsch waterproof connector pigtails
so you wouldn't need to crimp the connectors

 

[Hoggdoc]

that's a good choice as well ebay has Assembled Deutsch waterproof connector pigtails
so you wouldn't need to crimp the connectors

Maybe but then you'll need to connect them somehow and that will make the connection not as neat.

 

[Rudy]

Maybe but then you'll need to connect them somehow and that will make the connection not as neat.

Thank you.
Are they very bulky?

 

[HumanPerson]

Thank you.
Are they very bulky?

https://www.amazon.com/Deutsch-Connectors/s?k=Deutsch+Connectors

 

[Rudy]

https://www.amazon.com/Deutsch-Connectors/s?k=Deutsch+Connectors

Thank you for link.
I have been looking at every connector?
Was gonna go with Dean connectors cause they are very compact. then found out they fail sometimes.
Reliable is most important for me.
As for deutsch connectors .
My last question is I have to buy their crimper?
I can't use a standard wire crimper?

 

[Rudy]

Don't mind buying thier crimper.
Just need to know if it is essential.
I want my wiring to be as professional as possible.

 

[HumanPerson]

Thank you for link.

My last question is I have to buy their crimper?
I can't use a standard wire crimper?

If i recall correctly it's a star type of crimp, however.......
i've never used those connectors but i'd try .. just to know .. a regular connector tool like the one i use for the marine butt connectors.

 

[Rudy]

If i recall correctly it's a star type of crimp, however.......
i've never used those connectors but i'd try .. just to know .. a regular connector tool like the one i use for the marine butt connectors.

So are you saying a regular crimper would work?

 

[Rudy]

Thank you to everyone for your valued input.
I much appreciate.

 

[Freddy1]

So are you saying a regular crimper would work?

Simple answer, if you want a professional job .... no. You'll need the dedicated crimp tool. Same deal for just about every specialised small size connector. The run of the mill green/yellow/blue type electricians tool will not do the job properly.

 

[hsdrggr]

You could solder and heat shrink the connections. I probably wouldn’t solder the rear hub connector because it has to be removed occasionally. $9 for a 9 pin male and female Juliet connector. https://a.aliexpress.com/_mqByOtu

 

[ElHegpah]

I'm looking at the phase wire connection coming from the controller, the extensions connected appear to be a VERY much lighter gauge wire. These wires carry high amperage loads, a Multiple of supplied amps, and need to be spec'd for that, also ideally as short as feasible.

 

[hsdrggr]

I'm looking at the phase wire connection coming from the controller, the extensions connected appear to be a VERY much lighter gauge wire. These wires carry high amperage loads, a Multiple of supplied amps, and need to be spec'd for that, also ideally as short as feasible.

Yes, you are 100% correct. I looked again at the OP and noticed he’s talking about a 1000watt hub. So I would say that my original mention of the 9-pin julet motor connector is not up to the task. A newer style larger motor connector would be better. The L1121 11-pin, L1019 10-pin, and Z916 9-pin connectors are for higher amp loads.

 

[m@Robertson]

Speaking of amps, the Deutsch connectors I looked at have a 13a capacity and are suitable for 14-18 gauge wire. Thats not enough for many of the connections you will need.

For what I do, I use XT60's for battery charge terminals, and XT90S for controller-to-battery power. Both are highly water resistant and are so secure they need no locking mechanism. And for sure something robust for the motor-to-controller connection. All of my bigger hub motors use the Z916 but there are for sure other options out there. All the little stuff like PAS sensor, speed sensor, brake cutoffs and display plug is a Higo/Julet. Just say no to the spade connectors

Another vote here for crimping, plus the use of adhesive marine butt-end connectors and adhesive 3:1 heat shrink. Always with the proper tool never a pair of pliers.

 

[hsdrggr]

$18.18 67％ Off | Ferrule Crimping Tool HSC12 16-6 Tubular Terminal Mini Pliers For Large Size Terminals Electrical Clamps 0.08-16mm²/30-5AWG

https://a.aliexpress.com/_mOAMAZe

$4.60 33％ Off | 200pcs Butt Wire Connector Uninsulated Ferrules Electrical Cable Terminal Bare Tinned Crimp Terminal 0.5-6mm2 22-10AWG

https://a.aliexpress.com/_mPq5TWc

 

[m@Robertson]

As long as we're on the subject, I wrote up a how-to on doing crimping right, and list the tools I use.

How To: Safe, Reliable Electrical Crimp Connections (part 1 of 2)

Solder or crimp? Debate on that can be fierce. After more than 8 years of daily commute riding, I have never had a crimped connection fail. How is that reliability accomplished?

talesontwowheels.com

 

[thegman121]

re: cables and connectors, does anyone have as suggestion for where to go to get custom cables made? I'm comfortable soldering, but for a motor cable, I'd prefer to have something made with the correct length and connectors.

(specifically, I'm trying to get an L1019 (male) to L1121 (female) to connect a Grin Phaserunner to my Bafang G063 hub motor.)