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How to connect wires neatly and securely

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Photo 1. This is how the twist was before.
Photo 1. This is how the twist was before.

My wife brought from work an old boiler with an extended wire and asked to do at least something with it, otherwise it was scary to use it because of the unsightly connection. It might have served as well, but it looked a little scary indeed. Well, how can you not help your beloved?

First, the old twist had to be completely cut and the ends of the wires were stripped. It turned out that they also have different sections.
Photo 2. Prepared ends. The thinner wire is stripped more.
Photo 2. Prepared ends. The thinner wire is stripped more.

The wire of the boiler, which is thinner, was stripped slightly higher than the other so that it could be put on the ends pieces of yellow heat shrink and bring them above the bare part.

On the other wire, which is gray, I also put on a piece of gray heat shrinkable about 10 cm long. In size, it was slightly larger than the diameter of the wire itself in the insulation.

Further made the usual spiral twist of the veins and soldered the strands with a thin layer of solder so that they would not stick out. He moved thin pieces of heat shrinkage to the places of the adhesions and heated them with a gas burner to sit in place.

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Photo 3. Insulated brazing prior to heating with a torch.

At the next stage, I removed a piece of insulation from a completely different round wire and cut it lengthwise so that you could put the twists in place. In essence, this isolation became a continuation of the native isolation; she further protected and straightened the wire. Here, of course, there were some inconveniences, but still it worked out.

I realized that if the wires were of the same cross-section, then the soldered strands would definitely not fit into a piece of white insulation.

Photo 4. Applying a layer of additional insulation.

In the end, I also had to work a little to pull a piece of the second heat shrink on top of the connection and start it on another wire. Then there was the thought that this gray tube should have been initially put on a less thick white wire, and not on a gray one, and that would have been easier.

Photo 5. Almost finished connection. It remains only to warm up the heat shrinkage with a burner.

In the end, the connection came out pretty good and much more accurate. My wife looked, smiled and calmed down. In the end, I was satisfied. It is clear that the method is not the easiest and a bit confusing, but it's worth it. Write what you think about the result.

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