How to Solder 4-Gauge Wires

In North America, the guide to denote the thickness of wires is called the American Wire Guide (AWG). The smaller the number of the wire, says the AWG, the thicker it is and the more amperage it will conduct. As a comparison between wires, regular household wiring is 14-gauge in thickness and rated at 15 amps, while 4-gauge wire is rated at 60 amps. Because 4-gauge wire is thicker, you'll need a hot soldering iron to heat the wire adequately.

Soldering gun or iron--45 watts minimum
Damp sponge
Silver solder
Needle-nose pliers
Electrical tape or shrink tubing

Instructions

- 1
  Plug in the soldering gun or soldering iron and allow it to heat up to operating temperature.
- 2
  Tin the soldering gun or soldering iron tip by wiping it off on a wet sponge, then lightly rub a bit of silver solder over it.
- 3
  Tin the wires to be soldered by heating each wire individually until a bit of solder melts into the strands.
- 4
  Set the two tinned wires side by side and place the soldering gun or iron beneath them while touching each one. When the solder on the tinned wires begins to melt, touch a piece of solder on the top between both of the wires. The heat of the gun or iron will draw the solder downward, securing the wires together.
- 5
  Wrap electrical tape around the solder joint tightly to insulate it. An alternative is to slide some shrink tube over the joint and heat it until it shrinks and forms a tight seal.

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