PREFERRED

GENERAL REQUIREMENTS

The splice exhibits a smooth profile, proper strain relief, and is located in an area of the harness not subjected to flexure.

Best Workmanship Practice

PREFERRED

SPLICE ASSEMBLY PROFILE

The location of splices shall be staggered to minimize the increase in profile to the harness. Final assembly profile shall not impact form, fit or function.

Best Workmanship Practice

PREFERRED

SPLICE RESTRAINT

Cable ties/lacing shall be installed at both ends of a splice or solder sleeve, but placement shall not violate stress relief requirements.

Best Workmanship Practice

ACCEPTABLE

CRIMP SPLICE-BUTT/INLINE

The contact has been deformed only by tool indenters. Indents are symmetrical and centered on the crimp barrel. No exposed base metal or other damage. Wire strand ends are visible. Proper insulation spacing (C).

NASA-STD-8739.4 [19.6.1.c]

ACCEPTABLE

CRIMP SPLICE - END

Tubing is tight and symmetrical. Overlaps meet minimum electrical spacing, while providing strain relief. The termination is visible. Conductor(s) exhibit proper bend radius and strain relief.

NASA-STD-8739.4 [19.6.1.c]

ACCEPTABLE

CRIMP SPLICE - PARALLEL

Tubing is tight and symmetrical. Overlaps meet minimum electrical spacing, while providing strain relief. The termination is visible. Conductor(s) exhibit proper bend radius and strain relief.

NASA-STD-8739.4 [19.6.1.c]

ACCEPTABLE

LASH SPLICE
END

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

LASH SPLICE
INLINE

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

LASH SPLICE
INLINE BRANCH

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

LASH SPLICE
SHIELD TERMINATION (INLINE/RUNNING)

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

LASH SPLICE
SHIELD TERMINATION (TRADITIONAL)

The termionation is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk with proper strain relief.

Best Workmanship Practice

ACCEPTABLE

SOLDER SLEEVE SPLICE
INLINE

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

SOLDER SLEEVE SPLICE
INLINE BRANCH

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

Best Workmanship Practice

ACCEPTABLE

SOLDER SLEEVE SPLICE
SHIELD TERMINATION (INLINE)

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

NASA-STD-8739.4 [11.4], [19.6.1]

ACCEPTABLE

SOLDER SLEEVE SPLICE
SHIELD TERMINATION (TRADITIONAL)

The termination is fully wetted, smooth and shiny. Conductor contours are discernable. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces.

NASA-STD-8739.4 [11.4], [19.6.1]

ACCEPTABLE

WESTERN UNION/LINEMAN SPLICE

The termination is fully wetted, smooth and shiny. Tubing is tightly shrunk, with proper strain relief, overlap and no exposed conductive surfaces. Western Union splices are used for solid conductors.

NASA-STD-8739.3 [13.6]

UNACCEPTABLE

EXCESSIVE PROFILE

The location of splices shall be staggered to minimize the increase in profile to the harness. Final assembly profile shall not impact form, fit or function.

Best Workmanship Practice

UNACCEPTABLE

IMPROPER RESTRAINT

Cable ties/lacing shall not be installed across the splice/solder sleeve body, unless sufficient protection is provided to prevent compression damage to the termination and/or to the insulation of adjacent conductors.

Best Workmanship Practice

UNACCEPTABLE

IMPROPER SPLICE GAUGE/SIZE

Replacement conductors shall be of the same voltage and current rating as the original conductor.

Best Workmanship Practice

UNACCEPTABLE

SPLICES IN FLEXURE ZONE

Splices shall not be installed in areas where the harness is designed to flex.

Best Workmanship Practice