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Joe Ewen wrote:
I second Al opinion on not using soldered Dsub connectors. In my opinion crimped Dsub connectors are more professional and potentially reliable. Soldered connections are more prone to corrosion, cold solder joints, crystallizing and breakage from vibration. I am not saying I do not have any solder joints in my airplane, but there are none anywhere in the engine controller circuit. If you are looking for a source for milled pins - Steinair.com, $25 /c for pins and sockets. Crimped (milled) pins and sockets are much easier and IMO result in a more professional installation.
snipped
I must respectfully offer a somewhat modified view.
In general, crimped connectors are only reliable if done with very high quality crimpers, costing many 10's to hundreds of dollars. In a production environment, big bucks for a crimper means any klutz who can squeeze can be very productive.
Soldered joints are prone to corrosion only if corrosive flux is used. Improperly crimped pins can have corrosion within the joint, just like a riveted or bolted structural joint. Crystallizing is a product of improper technique, not the soldering process itself. Breakage from vibration is an issue with either technique; the stress riser on a crimped joint is much sharper than a soldered joint. Proper support just outside the joint is the remedy, whichever process is chosen.
Milled pins are certainly better than the rolled sheet metal pins, but with proper technique, they can be soldered with relatively inexpensive equipment.
FWIW,
Charlie
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