Western Union Splice

A Western Union wire splice is a highly reliable, strong, and durable method for joining solid or stranded electrical wires end-to-end, designed to resist tension and reduce electrical resistance. The technique involves stripping, crossing, and wrapping wire ends tightly, followed by soldering and insulating with heat shrink tubing. It is ideal for permanent, high-strength connections.

How to Make a Western Union Splice

1. Prepare wires: Strip approximately 1–2 inches of insulation from both wires using wire strippers. Slide heat shrink tubing onto one wire for later use.
2. Cross and twist: Cross the bare wires together at a 90-degree angle, about one-third of the way from the insulation.
3. Wrap ends: Wrap one wire end tightly and uniformly around the other wire (approx. 3–5 times), keeping the wraps tight. Repeat on the opposite side with the second wire, twisting in the opposite direction for a "knot" appearance.
4. Secure and solder: Ensure the ends are tucked down. Use a soldering iron to apply solder for a permanent, low-resistance connection.
5. Insulate: Slide the heat shrink tubing over the finished joint and apply heat to seal.