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Hi Bill,
"Did the bullet connectors fail before you wired the firewall connections direct?"
No. The corrosion on these brass connectors never got that bad. Besides I was doing the cleaning once every few years. I got tired of doing this so soldering them was the solution. I also realised the 900 harness generally don't need replacement unlike those on 200 700 series. Plus I don't see any replacement harness for 900 series on Dave Burton's website while it was still up last time.
"Would filling them with dielectric silicone initially have extended the life of those connectors?"
Yes.
"Did you use non-insulated butt crimps before soldering and shrink wrap?"
No. I just strip-off the wire's insulator and twist them together before soldering. Remember to put the shrink-wrap down the wire before soldering. If you solder for too long the heat transfer might shrink the wrap before its intended use so put some insulator under it, maybe a small piece of paper or masking tape. You can't park the shrink-wrap further down the wire while soldering as the rest of them is under plastic tubing. Some bigger gauge wire might need longer (5-10 seconds) soldering time and repeated soldering. Using a 30-40 watts soldering iron is a must as soldering these wires need more heat than those on circuit boards.
"Perhaps the general disdain for after market CPS's might be caused by un-plated connectors acting up with dis-similar metals for contacts?"
Its possible. Haven't think of that before. Yes zinc paste might be helpful.
Best regards,
Amarin
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