I have several light sets from after-Christmas purchases at Lowe’s, etc. These consist of two, three, or four light posts connected to a small battery container (3xAA) that also accepts a 3V wall wart.
I want to cut the wires from the lights to the battery box, run the wires through the layout, and connect them underneath to the power supply. But I do not want to solder these wires; instead, I would like to use a wire nut or other simple mechanical splice that can be easily undone if necessary.
The problem is that these wires are very small, I guess around 28 AWG, and I can’t find any splice connectors that work on them. (Also, striping the wires also is rather difficult, so an insulation displacement connector would be best.)
Some of the really small wire splicing, i.e. Telephone type wiring splice, 20, 22, 24 gauge and smaller, can be done with specialty telephone connectors. Note that these types of connectors are usually for solid wire. Most do not require insulation removal. Insert the two wires, push the yellow cap down with side cutter/plyers on the two wires.
If you get to the point where this size of wire is used a lot, (example) Signaling system, low wattage application, you may want to consider a Telephone punch down block and the appropriate punch down tool. This block requires a 66 tool/cutter, there are other terminations requiring a 110 tool/cutter. For One and Two splices/connections either of the connectors shown above does a very good job.
Solid terminal strip (4) connections per horizontal row. There are strips where the two left terminals are seperate from the two right terminal possibly requiring a bridge clip. Picture is telephone not train wiring.
Note that 28 gauge wire is small for telephone/com wire. Pictured is 24 gauge. Installation with the correct tool requires no stripping of the insulation, the impact tool/s listed above also cut/s the wire once installed. IMO an expensive tool.
One problem I am encountering is that most of the connectors will work with wire down to 24AWG, solid. The wires these lights have are stranded, five 0.004 wires, which is smaller than 28AWG, and are very difficult to handle. I have stripped them and twisted them together, and this may be as good as it gets.
One problem I am encountering is that most of the connectors will work with wire down to 24AWG, solid. The wires these lights have are stranded, five 0.004 wires, which is smaller than 28AWG, and are very difficult to handle. I have stripped them and twisted them together, and this may be as good as it gets. You could twist and then tin the very fine strands with solder, which might make it a bit more workable in a small mechanical connector.