Easy way to replace bullet connectors

Posted this on the Midget forum, but thought you all may be interested too.

I just tried this tonight and it worked pretty well. Not rocket science, but I thought I'd share.

I needed to put bullet connectors on the ends of 2 wires for a rebuilt side marker light. I had some old extra wires that had good bullet connectors on them. So, I snipped off the old wires from the extra connectors. I then gently clamped the connectors in my vice and took a small drill bit and drilled out the old wire and solder about a 1/4 inch into the connector.

I then stripped the new/good wires and test fitted them for length in the drilled holes.

Next, I heated the connectors (Still clamped in the vice) with my torch and melted solder directly in the holes. Then I inserted the new wires and let the solder cool.

Looks just like factory installed bullet connectors!

Bryan

I have used a similar process and it worked well, but, to remove the connectors from the old wires I used my small soldering torch to melt the solder and pulled them off.
Saved using the drill.

Rich

I bought a bullet crimping tool from British Wiring, and use the 'crimpable' bullet connectors from Moss. Had to do it for the exact reasons as you. They come out exact duplicates of the original wiring harness ends.

http://www.britishwiring.com/CAT28_29.PDF


It's tool TT85

I hate that darn bullet crimper! A waste of fifty bucks for me. I soldered everything.

Rich,

I tried that (heating them and pulling out the old wires) initially too. For some reason mine didn't want to come out easily and ended up catching the plastic wire sheath on fire.

The drilling worked surprisingly easily. In fact on my first one I accidentally drilled all the way through the connector.

Bryan

What is the trick to getting a stuck Male bullet out of the Female side? I pulled the wire right out on one of my ground connections.

> What is the trick to getting a stuck Male bullet out of the Female side? I pulled the wire right out on one of my ground connections.

Pull out the other side, then force a small screwdriver (or whatever) through the hole and push the stuck one out.

The trick is to pull the bullet off. If its poorly connected, let it come apart, then fix it! You don't want to baby a poor fitting! The bullet should stay on no matter what!

Thanks Guys, Fixing it is what I wanted to do Jeff

pmittler Wrote: