Restoring Rusty

[hatzie]

Originally Posted by Gregski

the drive side headlight wiring harness section proved trickier as it is the middle section of the daisy chain run

I'm gonna have to come back, and cut ans splice the headlight plug 3 inches over so it's not that tight when I plug it in (I am currently out of butt connectors)

Don't use insulated Butt Conectors. They will come loose and cause all kinds of grief.

Solder and Heatshrink the connection. I generally use "Marine Grade" Adhesive Lined heat shrink on connections that will be exposed like these.
Radio Shack 60/40 Sn/Pb rosin core solder is generally pretty smoky. I use Kester 44 .80mm 66/44 Sn/Pb and MG Chemicals Liquid Flux on old wires. <---That 1lb spool and tiny bottle is a lifetime supply. You can wipe off any excess flux with Ispropyl Alcohol.
Use a wet sponge to clean the tip. It'll clean off the corrosive burnt flux leavins and oxidized lead and tin. You won't have to use tip-tinner cleaner as often, or maybe at all, if you keep the crud off the tip by wiping it often.
A third hand tool can be built with ROMEX and alligator clips... See the first few minutes of the last video. Eric uses a soldering gun. I don't recommend a soldering gun it's way to difficult to control the heat so it's way too easy to burn the wire jackets off.

http://www.youtube.com/watch?v=Q9G9gaokqvM

http://www.youtube.com/watch?v=aoD2aUvnQXg

https://www.youtube.com/watch?v=L61LJcz7H6g