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By Dose Pipe Sutututu · Posted
I usually rip off the insulation off those terminals and crimp them down without it (to get a better crimp) then heat shrink over the top. Man, just PWM your fuel pump and enjoy life lol. -
I'd try the Jaycar one first. Don't even bother with replacing the passthroughs, as they will still work provided the melting is only minor and they still seal and insulate. You can always go back and replace those later. After you've put the new crimps on, you just have to make the pump work for a bit, then go back there and laser gun the terminals (or touch if you're brave enough) to see if they are sufficiently cool to relieve your concern. You might want to gather a data point with the old setup first, to see how hot they get now. -
By Murray_Calavera · Posted
This might be another option too if the surgery allows for a straight lug to be used. Jaycar rates them at 30 amps - https://www.jaycar.com.au/6mm-non-insulated-eye-terminal-4mm2-pack-of-8/p/PT4932 -
By Murray_Calavera · Posted
@GTSBoy Makes sense. I'm guessing we'd have to use a cable lug, its tricky finding lugs suited for wire smaller then 0 gauge, but this looks like it might work? https://au.element14.com/panduit/lca10-10f-l/terminal-compression-lug-10-10awg/dp/2944903?CMP=KNC-GAU-GEN-SHOPPING-PLA-PMAX&mckv=_dc|pcrid||pkw||pmt||slid||product|2944903|pgrid||ptaid||&gad_source=1&gclid=CjwKCAjw4ri0BhAvEiwA8oo6F3hR5QEQH43vntEUad27nYgwWzBmgdiYNqiQLBMe3C9pkkncxgv3oRoCciEQAvD_BwE Just need to do some surgery on the bottom of the bulkhead as even fitting the tiny ring connectors space is tight. But now that I'm in this situation, do I buy another stock bulkhead and give the bigger lugs a go or do I just drop $1000 on a frenchy setup? Hmmm. -
Yeah, see, I think I've worked out what is happening here. You (and other people) buy these massive "40 amp rated" pass throughs, and use fat wires, then make the connection between them using a ring crimp that has a much smaller cross section in that piece in the neck between the crimp and the ring terminal than any other part of the system. And it gets hot there. And because it is very well connected to the passthrough....that gets hot too. We probably need to be using more chunky wire terminations.
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