T&T: Electrical Wiring

[capteric36]

 After my electrically assisted bicycle fell into 
the S. F. Bay last April I undertook to make 
certain repairs and improvements.
 One of these was to build a new controller for 
the Zap electric motor system. The system as it 
came from the factory (about 9 years ago) had a 
few problems I did not want to recur. Such as the 
switch that turned on and off the current to the 
control box. That switch became balky after about 
2 years. I had to repeatedly turn it on and off to 
get the system to work. Very frustrating when I 
had just shut it off a few minutes earlier.

 To make a long story short I have built a 
'controller' that has all gold plated connections. 
I used 8 AWG marine grade wire for all short runs 
and 4 AWG marine grade wire for long runs. I used 
gold (24 carat 'pure' gold plating) plated crimp 
on, closed end, ring lugs for every connection 
both inside the new 'control box' and outside of 
it. I used gold plated bolts and washers and wing 
nuts for every 'through a panel' connection.
 Of course I was unable to find any source for 
gold plated circuit breakers that were rated at 60 
amps or more, so I used a waterproof marine 
circuit breaker instead. This also serves as the 
on-off switch.

 When I rewire my boat I will be trying to use the 
same concept of gold plated connectors everywhere.
 These ring lugs are getting harder to find but I 
still have a few sources. I will be ordering a 
bunch more ring lugs over the next few months as 
the manufacturer no longer makes them. They are 
brass, seamless and closed end. They are VERY 
sturdy and difficult to crimp (I have to use most 
of my body weight on the ratcheting crimper to get 
the job done) so I expect them to last longer than 
I will.

 Oh yeah, all connections sealed with the 3-to-1 
shrink tubing with the internal heat glue to 
prevent any moisture wicking up the wires.
This IS costing me a lot compared to just making 
it work, but I expect it to last until I die with 
no further problems, as long as I keep it the H-LL 
OUT OF THE BAY!!!!!

 Just my $0.02 worth for tonight.

Eric Thompson
S/V Procrastinator
South San Francisco
capteric36 at sbcglobal.net