So I had an idea on making my own waterproof connectors based on a 5.5mm bullet connectors so able to handle the high amps (100a+) needed for efoil.
They are now complete and first field test will be at the weekend but the build is looking solid.
The connectors are based on standard ip68 cable glands.
I 3D printed a plug which is epoxied into the “dry” part of the gland. And a cable with a 5.5mm bullet connector soldered on is epoxied through the centre of the plug. Step by step images below.
Basically the plug inside the gland with the bullet female connector allows a 5.5mm male to be inserted from the wet side of the gland (through the cap and rubber seal). Once inserted the gland it tightened for a fully waterproof connectors.
A side advantage is that once the plug is glued in the gland, it seals the gland completely. So even if there was a small leak from the gland seal, no water will reach inside. I use this on my electronic box so the mast and motor can be completely removed but I guess it can be used on batteries or anything else.
My board has a wet area just before the control box where the wires route from the mast. Check the build thread.
First up I made some patch cables with awg8 silicon cable and 5.5mm bullets.
Next, these were epoxied into the 3D printed gland plugs just proud of the 3D print. I’ll share the stl files tomorrow. I had to print scaled up a little but it’ll depend on your parts and printer. The aim is for the connectors to be a tight fit, so you can just about remove by hand, untill you glue them of course!
Glued in and sanded back to give a key for the next batch of glue
Next, glue these into the glands. Remember to be very careful not to get Epoxy into the plugs!
My glands are already glued into the electronics box but if you can do this before installing it would probably be easier
Then you pretty much done!. See the connectors inside the gland.
You can theb insert and remove the bullet connectors from the outside.
I don’t have the rubber seals and caps in place here but as long as you neat with your soldering on the bullet connectors it will slip through these too
All done and ready for action!
Just insert cabled and tighten the glands.