CRIMPING 6 pages of detail

[Gorminrider]

http://www.pbase.com/mainecruising/wire_termination&page=1

a good read if you want to make repairs changes in your electrics... boats and motorcycles have a lot in common

[glib]

Very helpful. I knew these cheap aluminum terminals were crap but it seems they are everywhere. Also I didn't know there existed crimping tools of such high caliber.

[posplayr]

Open barrel is the only way to go.

http://vintageconnections.com/

Those PVC terminal have DIY written all over them and can't be soldered without butchering the insulations.

[850GT_Rider]

For many applications, and especially military, aircraft and aerospace, the only crimpers that can be used are those specifically designed or designated by the termination manufacturer for the particular termination. Crimping specifications will then include what settings to use on that particular tool. For example, can't use a Panduit crimper for Amp terminals.

Nearly all the correct crimpers will be of the ratcheting type that (when set properly) automatically compress and crimp only as far as needed, then release. It could be compared to using "clicker" type torque wrenches.

[BigD_83]

That was a long read for what was essentially an advertisement of a particular tool, but filled with loads of good information. Makes me happy I bought a decent crimping tool along with my vintage connectors

[posplayr]

For many applications, and especially military, aircraft and aerospace, the only crimpers that can be used are those specifically designed or designated by the termination manufacturer for the particular termination. Crimping specifications will then include what settings to use on that particular tool. For example, can't use a Panduit crimper for Amp terminals.

Nearly all the correct crimpers will be of the ratcheting type that (when set properly) automatically compress and crimp only as far as needed, then release. It could be compared to using "clicker" type torque wrenches.

For all these reasons is why I recommend for the DIY type to buy ONLY one of these if you want to avoid spending $2K on a fully selection of crimpers. It is the most versatile crimper becuase it does not combine insulation with conductor crimp and it is a parallelogram type v.s. scissor type crimper which does not twist the crimp.

http://www.ebay.com/itm/Molex-Style-Crimp-Tool-Wiring-Harness-Crimper-Crimping-Opening-Barrel-14-24-AWG-/111664869648?hash=item19ffbeb110:g:NeIAAOSwie5XS-lT

For the motorcycle environment I couple this with small amount of solder directly at the end of the crimp (avoiding wicking beyond the insulation crimp) for mechanical and electrical reliability.

I have been using this same crimper to crimp 2.5mm JST contacts; I used a grinding wheel to narrow the jaws to about 3 mm.

[Gorminrider]

"the only crimpers that can be used are those specifically designed or designated by the termination manufacturer" and "open barrel only"- I hadn't thought of that!...varying insulation thickness and what-all? So the open barrel crimps once made can be insulated with shrink tube? That sounds like the most versatile way for sure.
I just got some open-barrel spade connectors from local store thinking they were merely useful for the motorcyle's multi connectors but I had to order them. ALL the auto outlets are very strong marketing collections of the vinyl coated connectors and have certainly led ME astray. RETHINK! eh?

[tkent02]

Until I ran out of aircraft crimp connectors that's what I used. Shrink tubing over them works great. Need to get more, they are good if you have the right tool. Haven't found any of decent quality anywhere, can't find any connectors without the stupid plastic parts which make proper crimping impossible. I guess I should go visit the local boat place.

[BigD_83]

I'm sure many of the long-time members here know of these guys, but for others who don't:

http://vintageconnections.com/

The crimping tool they offer is pretty good, but I do find it a smidge wide for some connectors. I never thought about grinding the jaws like posplayr has.

[Gorminrider]

Tkent, per "I guess I should go visit the local boat place". No-you don't want to do that! anything for a yacht has a huge premium... though every so often commercial chandlers can be good...
I ordered at my auto-parts place....

I like that vintageconnections.com! but shipping and exchange rate keeps me hunting around the local town. I expect I can get all that here but it needs more hunting about.

[60ratrod]

For many applications, and especially military, aircraft and aerospace, the only crimpers that can be used are those specifically designed or designated by the termination manufacturer for the particular termination. Crimping specifications will then include what settings to use on that particular tool. For example, can't use a Panduit crimper for Amp terminals.

Nearly all the correct crimpers will be of the ratcheting type that (when set properly) automatically compress and crimp only as far as needed, then release. It could be compared to using "clicker" type torque wrenches.

I've used them many times on EA-6B jets. some sets come with interchangeable jaws for different size terminals. they can be a PITA in cramped spaces or with short wires. the ones I'm most familiar with are the ones that use 4 pins 90* apart from each other that compress 4 sides of the terminal. I actually kinda like and miss those. otherwise what I like to do is solder wires together and if I have to put a terminal on, I remove the plastic insulator, put a SLIGHT crimp on the terminal, then finish by soldering the terminal to the wire and then run some heat shrink over the soldered part of the terminal

[tkent02]

the ones I'm most familiar with are the ones that use 4 pins 90* apart from each other that compress 4 sides of the terminal. I actually kinda like and miss those.

I have that crimper, left over from when I was an electrician at Boeing, but can't find the connectors for it anywhere. It really worked well until Boeing Surplus closed it's doors and I ran out.

[60ratrod]

I have that crimper, left over from when I was an electrician at Boeing, but can't find the connectors for it anywhere. It really worked well until Boeing Surplus closed it's doors and I ran out.

it won't work with unshielded connectors? I say unshielded cause some of the pins I had to crimp were TINY! I'd think that unshielded connectors or connectors with the shields removed would work ok.

[bobgroger]

Boeing Surplus. I loved that place in its early days. Went downhill towards the end....

[sailorman1617]

http://www.pbase.com/mainecruising/w...ination&page=1

a good read if you want to make repairs changes in your electrics... boats and motorcycles have a lot in common

When I first saw this link, I thought I was on my sailboat forum by mistake; since that is Mainsail's page :-)