Waterproofing Electrical Connectors
Discussion
I was having difficulty waterproofing an electrical connector on a 1980s KTM enduro bike. It is a multi-wire connector and the slightest damp would cause a barely-detectable misfire as moisture affected the signal for the electronic ignition.
I tried using a medical product 'Tegaderm' which is a waterproof protective patch to go over dressings and pain patches like Fentanyl. I noticed that this product is a real pain to remove every few days when I need to change my patches, but they sure are waterproof and adhere like beer to one's career.
I cleaned the connector block with brake cleaner and wrapped the patch around it. They are practically invisible in use, removal is helped with the aid of a Stanley knife.
They are cheap. often free (pharmacies get lots of free samples of just about everything that's harmless) if you ask. The best feature is that they are really stretchy and mould themselves to any shape. Avaiable in a multitude of sizes, they may also work as a protector for small decorative parts such as enamel or acrylic badges and other parts that you would like to protect from tarnishing.
I tried using a medical product 'Tegaderm' which is a waterproof protective patch to go over dressings and pain patches like Fentanyl. I noticed that this product is a real pain to remove every few days when I need to change my patches, but they sure are waterproof and adhere like beer to one's career.
I cleaned the connector block with brake cleaner and wrapped the patch around it. They are practically invisible in use, removal is helped with the aid of a Stanley knife.
They are cheap. often free (pharmacies get lots of free samples of just about everything that's harmless) if you ask. The best feature is that they are really stretchy and mould themselves to any shape. Avaiable in a multitude of sizes, they may also work as a protector for small decorative parts such as enamel or acrylic badges and other parts that you would like to protect from tarnishing.
Model cars I used to take a long rubber ballon. Cut both ends off so you have a stretchy rubber tube.
Put the connection inside the tube. Put a zip tie on either end as close to the connection as possible.
Then cram Vaseline in each end and put another zip tie on.
In effect you should end up with the following.
Zip-vasaline-zip—connector—-zip-vasaline-zip
Used to blow up quite a few electronic components racing off road buggies in the rain and mud in the 80s until some old boy at the club showed me how to do it.
Only instead of only putting a connector
In this setup I would often put electronic speed controllers inside a larger ballon and sealing the whole lot in.
I’ve lost count of the number of futaba speed controllers I blew up over the years.
I realise this is a motorbike but the principle still stands so long as it’s not near somewhere absolutely red hot.
In which case I would try some self amalgamating tape like we use on the herc f130j to protect the engine connections in a hot environment. We always called it greenline or self amalgamating tape. The line colour denotes the temperatures it’s good for.
https://www.termtech.co.uk/Catalogue/Tapes/Self-Am...
Something like this perhaps.
Put the connection inside the tube. Put a zip tie on either end as close to the connection as possible.
Then cram Vaseline in each end and put another zip tie on.
In effect you should end up with the following.
Zip-vasaline-zip—connector—-zip-vasaline-zip
Used to blow up quite a few electronic components racing off road buggies in the rain and mud in the 80s until some old boy at the club showed me how to do it.
Only instead of only putting a connector
In this setup I would often put electronic speed controllers inside a larger ballon and sealing the whole lot in.
I’ve lost count of the number of futaba speed controllers I blew up over the years.
I realise this is a motorbike but the principle still stands so long as it’s not near somewhere absolutely red hot.
In which case I would try some self amalgamating tape like we use on the herc f130j to protect the engine connections in a hot environment. We always called it greenline or self amalgamating tape. The line colour denotes the temperatures it’s good for.
https://www.termtech.co.uk/Catalogue/Tapes/Self-Am...
Something like this perhaps.
Edited by MB140 on Saturday 11th June 13:25
Edited by MB140 on Saturday 11th June 13:27
I use Sureseal connectors for wiring exposed to the elements. Each connector housing is a single rubber moulding. The terminals are pushed inside the moulding far enough for the moulding to seal tightly against the insulation of the wire.
When the two housings are mated together the whole assembly forms an air tight seal from the insulation on one side to the insulation on the other.
Installing the terminals takes more work than for a typical push-and-click housing, but once assembled they really are superb.
When the two housings are mated together the whole assembly forms an air tight seal from the insulation on one side to the insulation on the other.
Installing the terminals takes more work than for a typical push-and-click housing, but once assembled they really are superb.
Toyota put what looks like a squirt of white grease into exposed connector plugs during production of some their off road range, Prado/Landcruiser/Hilux, never have any issues with corrosion at those points nor with disconnecting whenever necessary.
Don't suppose its the typical white grease you can buy at any motorists shop but hopefully give you another possible solution.
Don't suppose its the typical white grease you can buy at any motorists shop but hopefully give you another possible solution.
Baldchap said:
I'm a fan of putting heat shrink tubing over and sliding out of the way, soldering the joint, coating it in ACF50, and then shrinking the tubing over it all. Strong, small, and water/corrosion-proof.
The only addition I'd make is to use the glue lined heatshrink. If you get the 4:1 stuff, you can generally slide one end over the physical plug, and shrink the rest over the wire. Totally waterproof.Gassing Station | Home Mechanics | Top of Page | What's New | My Stuff