What connectors do you use for high amperage connections? I have burned up my fan connectors for the last time. I am an old RC car racer, and might switch to Deans plugs which will melt the wires off before the plug melts, what do you guys use? My fans pull roughly 35amps on in-rush and then settle in around +20amps....I had 12ga wire and wire nuts, but the wire nuts ended up looking like glo plugs....and melted off. This was after the weather pack plugs melted off.

So I am switching to 10ga wire and probably Deans plugs for those, but figured I would ask.

Deans are a good idea to me! Or Race Prep, lol.

Metripack 280, water tight and good for 30 amps continuous.

All I use is Duetsch connectors these days, or Milspec bulkhead connectors. It costs more but NEVER had an issue. Also a HUGE fan of floating ground systems.

No relay ? Doug

Metripack 280 is good for 30 amps, Metripack 430 is good for 42 amps. You can buy that stuff from Amazon, maybe other places. It goes together easy and is weather tight. Metripack is the modern Delphi standard so it is used on most GM vehicles.

As mentioned, any high current device will benefit from a relay to carry the load. If you are carrying enough amperage to melt connections then either the device is drawing too much amperage, wire size is not big enough, or maybe a grounding issue. I solder and heat shrink all my connections, and any plug-in connectors have to be designed for the amperage involved. Many years ago, I bought a small block Vega, and my first race I was in the finals, lost because car would not fire due to corroded wiring connections, after that I was very careful of wiring, cost me $1,000 purse.

Maybe I should mention, this was on a pre-wired Painless setup supposedly good to 40amps per circuit.

Honestly, I would be looking for a different fan set up. I've used all kinds of fans - dual set ups, big, little 10 or 12 amps is plenty. No idea how you get to where you are.

That should cure it. 35 FLA is too much for # 12 and 20A is about max, I just went thru this with a buddy's Derale set up.