How to waterproof ebike connectors?

miro13car said:

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ABsolutely they DELPHI Weather Pack they are not.
They are not Dephi brand.
Of course DELPHI connectors have a place on ebike, of course they are bigger than flimsy powerpoles and other cheap stuff.

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Yes - you are quite right - these are not Delphi - I mistakenly followed SM's link instead of the original SureSeal link. My remarks about size were aimed at the Delphi connectors - there is no doubt they will work, but the question is: what is the problem and what is an appropriate solution?

Phase connections are high amps and largely unaffected by water, ebrakes and halls are digital and not as susceptible to a little signal bleed. The common controller-ignition-wire kill switch carries Vbatt and must supply many ma to operate, so water is not much of an issue there. The analog throttle connection is the most susceptible to catastrophic failure (e.g. WOT) due to water or (Gnd) disconnect and should arguably be the focus of attention. This is not to say that issues cannot develop with the other connectors, but the standard tin plated connectors, proper crimping/wire size, and a little Permatex dielectric grease (auto parts stores) should do the job most of the time. Ensuring that high voltage phase/Vbatt connectors are not bundled with low voltage throttle/hall/ebrake connectors seems advisable.

Disconnects from corrosion is a derivative but different problem than immediate failures from water. It may be worth considering that if a connector cannot be sealed 100% forever, that it will eventually leak. Once water is in, it will have a hard time getting out (because of the sealing) and so will sit and corrode the connector/wiring. There is something to be said for not sealing some connectors at all and simply positioning or loosely shrouding them to keep them out of a deluge - leave them open so they can dry quickly and naturally.

I use the 'cheap stuff' in rain and snow and have no issues with water, loose connections, or other connector failures - this is not what I would use in competition, but for my application, just fine... My connectors are all open and unsealed.

Interestingly, there is no particular evidence that the OP's failure was connector-related at all - an assumption. It is just as likely that it was water incursion in the throttle assembly itself, in which case connector sealing/replacement will prove an ineffective solution and the problem will likely re-occur.... In that case, opening the throttle and coating the exposed hall leads and wiring with Liquid Lectric Tape (Home Depot, etc) will probably be more helpful.

Yes - you are quite right - these are not Delphi - I mistakenly followed SM's link instead of the original SureSeal link. My remarks about size were aimed at the Delphi connectors - there is no doubt they will work, but the question is: what is the problem and what is an appropriate solution?Phase connections are high amps and largely unaffected by water, ebrakes and halls are digital and not as susceptible to a little signal bleed. The common controller-ignition-wire kill switch carries Vbatt and must supply many ma to operate, so water is not much of an issue there. The analog throttle connection is the most susceptible to catastrophic failure (e.g. WOT) due to water or (Gnd) disconnect and should arguably be the focus of attention. This is not to say that issues cannot develop with the other connectors, but the standard tin plated connectors, proper crimping/wire size, and a little Permatex dielectric grease (auto parts stores) should do the job most of the time. Ensuring that high voltage phase/Vbatt connectors are not bundled with low voltage throttle/hall/ebrake connectors seems advisable.Disconnects from corrosion is a derivative but different problem than immediate failures from water. It may be worth considering that if a connector cannot be sealed 100% forever, that it will eventually leak. Once water is in, it will have a hard time getting out (because of the sealing) and so will sit and corrode the connector/wiring. There is something to be said for not sealing some connectors at all and simply positioning or loosely shrouding them to keep them out of a deluge - leave them open so they can dry quickly and naturally.I use the 'cheap stuff' in rain and snow and have no issues with water, loose connections, or other connector failures - this is not what I would use in competition, but for my application, just fine... My connectors are all open and unsealed.Interestingly, there is no particular evidence that the OP's failure was connector-related at all - an assumption. It is just as likely that it was water incursion in the throttle assembly itself, in which case connector sealing/replacement will prove an ineffective solution and the problem will likely re-occur.... In that case, opening the throttle and coating the exposed hall leads and wiring with Liquid Lectric Tape (Home Depot, etc) will probably be more helpful.

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SweetTrade324 said:

Do I just apply it directly with nothing else sealing it? Can I just spray the outside of the controller or do I open it?

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I would use it on your connections. I don't know how it would do with the heat. I had one of those cheap garage door openers I took it apart sprayed its down well let it dry and then ran water over it and it worked fine while the water was running over it and it has been on my bike for 2 years and countless rain rides.

I would use it on your connections. I don't know how it would do with the heat. I had one of those cheap garage door openers I took it apart sprayed its down well let it dry and then ran water over it and it worked fine while the water was running over it and it has been on my bike for 2 years and countless rain rides.

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