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I have followed the thread on electrical connectors for rudders and
such.  I agree with Brent Regan: every electrical connector is a
potential failure point, especially if you use a cheapie, and especially
if it in a place that can get wet.  The military and aerospace
industries use connectors by the millions, but they use high quality,
sealed, gold plated stuff, and you should too if you must use a
connector.  Tin plated connectors are not up to the job.  I

If you solder, remember that solder joints have ZERO fatigue resistance.
They can not tolerate ANY flexing or vibration or they are guaranteed to
fail.  Years ago our firm did tests showing that only 50 minor flexes on
a splice can cause a crack in the solder.  Therefore, if you solder, be
sure to use ample strain relief's and good anchors on both sides of the
splice to eliminate motion.  Or better yet, crimp and solder and have
enough extra wire that you can cut and resplice if you must part the
wires.  Solder is technically unacceptable for aircraft usage due to the
fatigue problem, but a joint that is soldered and crimped is durable,
and the solder will prevent corrosion in the crimp connection.  But in
any event, do not splice where the wires can flex. Anchor both sides of
the splice down, eliminate all motion at the splice, or expect a
failure, sooner or later.

Fred Moreno

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