Soldering Sucks, But Epoxy Potting Helps.

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Soldered connections are generally avoided in motorsport wiring applications where crimping is an option due to its superior attributes for this specific application.

BUT! There are exceptions where crimping isn't possible, and one of those exceptions is when we are potting actuators such as these Toyota ignition coils, which are known to fail when exposed to the comparably extreme vibrations motorsport use introduces compared to the drive to the shops Toyota thought you would be using them for.

In this video, Andre shows how this epoxy potting process is done and the extra step he likes to take with a moulded boot to increase the chance of long-term reliability.

TOOLS AND MATERIALS WE USED:
Soldering Station: Duratech TS-1640
Wire: Tefzel
Strippers: Ideal Ergo Elite with backstop
Sheathing: Raychem DR25
Epoxy Potting Mix: ResinTech RT125 or Hellermanntyton V9500

NOTE: We use what suits us and our application to the best of our knowledge based on our own research and industry experience. These are not the only tools or materials you can use for your own projects or hobbies, which might be very different depending on your application and budget. Educate yourself and decide what suits YOU best for yourself.
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TIME STAMPS:
0:00 - Soldered Connections Introduce Risk
0:48 - The Reason
1:06 - Part Design Flaws Require Solder
1:28 - How To Remove Soldering Risks
1:41 - Use Cases
1:48 - Stripping Tefzel
1:59 - Bend Before You Tin
2:16 - Soldering
2:31 - Backfire Feedback Connection
2:43 - Twist, Sheath
2:56 - Ensure A Strong Bond
3:12 - Strain Relief
3:30 - Epoxy Options
3:48 - Fill The Coil With Epoxy
3:57 - Go Have 24 Cups Of Tea And Wait
4:02 - Job Done, But Could Be Better
4:17 - Moulded Boot, Why?
4:34 - Prep The Coil
4:52 - Recover The Boot, Be Careful
5:12 - Epoxy Part 2
5:18 - Complete Potted Ignition Coil
5:29 - Anyone Can Fix This Known Fault
6:08 - BUILD.TUNE.DRIVE
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TAGS:
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