Working on a project, I was trying to make an LED connection to allow a shell to be removed easily. In doing so, I thought of another way to make a fairly small wire connector.
The idea is to use a piece of 0.010" phosphor bronze wire folded at the tip, opened back up slightly and inserted it into a 0.5mm ID brass tube. The springy wire makes for a nice fit that you have to pull apart.
Here are some pics:
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Cut a 3/16" piece of tubing off. Solder your intended wire inside the very end of the tube, making sure not to fill the tube, although it can be drilled out if you do. Solder the other wire to the folded rod.
The smaller you can make the pieces, the smaller the connection. A two wire connector, held together with shrink wrap is about 3mm wide and 2mm thick.
