Re: Molex connector crimps.
Dr. Slack, Tue Oct 28 2014, 11:25PM

They look like they're the matching parts, the 'use with's match, and yes, the correct crimp tools do cost an arm and a leg. However, what I've found with a similar terminal system, and may be your problem with this set, is that if you don't use the right crimp tool, the metal leaves that don't get crunched down the right amount get in the way of the little retention barbs that secure the terminals in the mouldings. That doesn't mean you have to buy the right crimp tool, but it does mean that you have to look at the mechanics very carefully, and figure out what should be where, and what you have to do to make it so. In my case, I found that the crimp leaves could be left in their 'as supplied' position, as long as I didn't use excess solder to attach the wire to where it would normally crimp. With a different system, YMMV.

Re: Molex connector crimps.
Thomas W, Tue Oct 28 2014, 11:33PM

Hmm, i given it a go, bending them in different ways. However it seems like the pin doesn't go in correctly, like the back tab that holds it in gets bent and does not return. It also looks like the pin won't go as deep into the connector as it should, like it gets stuck. Even if i cut the tabs off it still happens.

Re: Molex connector crimps.
Dr. Slack, Tue Oct 28 2014, 11:50PM

Yeah, sounds like evidence of not using the right crimp tool. These bent metal systems, it's a wonder they work at all, they truly are a wonder of value engineering. The bending and moulding tolerances mean that a single thou can be the difference between them working and not. The right crimp tool usually has a rachet thing that means they can't be released until the full compression cycle has happened, meaning that the terminal can't be removed until it meets its finished size tolerance. Persist with trying to figure out what is stopping it working. Section a housing with a scalpel so you can see the insides as the terminal goes in. It may help if you can get an already crimped terminal to see what it should look like, and where it catches.

Re: Molex connector crimps.
Thomas W, Wed Oct 29 2014, 12:29AM

Think i might just go with a different connector. these things are crap. I actually like IDE connectors more. or just buy pre-made wires.

Its stupid how bad these kind of connectors are really.

Re: Molex connector crimps.
2Spoons, Wed Oct 29 2014, 01:01AM

Actually they work really well if you use the proper crimp tool and the correct wire gauge

A properly made crimp should outperform a solder joint. It is gas tight, and has an integral strain relief (crimp on insulation).

Yes the tools are horribly expensive - because the dies are precision engineered to create the right force and shape for a specific crimp pin, and because they don't sell many.

Sometimes i've fixed retention problems by bending the little catch tab out a little further.

Re: Molex connector crimps.
Thomas W, Wed Oct 29 2014, 01:14AM

Thing is, i have been bending and reforming the metal on the connector. no matter what i do... it doesn't seem to fit :|

I think 6-10 pin IDE connectors are much better. quite cheap too

Re: Molex connector crimps.
Dr. Slack, Wed Oct 29 2014, 08:52AM


Think very carefully what you are saying. These 'crap' connectors sell billions of units, and they have been value engineered to be made for pennies, but are able to be assembled by unskilled people with a very high success rate, when using the specified tools.

Bear in mind the crimp tool may not just be making the wire crimp portion, but may also be deforming the rest of the terminal into the final shape required for the housing. What you have bought may be raw material to be finished into terminals by the crimp tool.

The connectors aren't stupid. It's stupid how you try to use stuff the way it wasn't intended, and then lash out at the stuff, rather than having the humility to look for and learn the lesson from the experience.

If you have a favourite connector, that you get on with, then I think using that is a good plan.

Re: Molex connector crimps.
Sulaiman, Wed Oct 29 2014, 10:20AM

I can confirm that when used with the correct crimping tool, Molex KK series are ok
(I prefer round pin connectors myself)
you may be flattening the part that crimps the conductors
when flat it will block the pin from entering the housing.

Without the correct crimping tool you will need to solder the wire
. using pliers squeeze the tabs around the conductors, first from both sides then 'wrap' the tabs over the conductors, do not close the part for the insulation
. Solder the wire in place
. when cooler squeeze the back part around the insulation
should be ok.

Re: Molex connector crimps.
mbd, Wed Oct 29 2014, 01:05PM

Having introduced myself to the 'art' of pinball maintenance in the last couple of years, I have managed to acquire some small skills in crimping various connectors.

I would like to echo the various comments above - a properly crimped KK connector is a fine thing.

My question is: what crimper are you using? Can you please post a photo? If you are using an ultra-cheap crimper, I don't think you have a chance of getting the crimp done correctly. (I know I never could.)

BTW you should be able to get an adequate crimper for less than USD50.

MBD

PS The general consensus among the pinball crowd is that IDC connectors are to be avoided. But then again, the pinball crowd is after longevity and reliability and maybe your application is not nearly so demanding.

Re: Molex connector crimps.
Thomas W, Wed Oct 29 2014, 01:08PM

I admit im just using a pair of long-nosed pliers to bend the pins and make it fit. I want to buy a crimper however im not sure which one i should be buying. if anyone has any good links i would really appreciate it.

As for IDC connectors, i don't really see how they are unreliable, expecially ones that are brought in from companies like Amphanol built as a 150mm cable with 2 IDCs on each end.
Expecially considering that many computers and very old peices of equipment use them and are still running fine 20 years later.

Re: Molex connector crimps.
Dr. H., Wed Oct 29 2014, 03:24PM

Good day Thomas,

If I am not mistaken - you need something like this -

Cheers

Re: Molex connector crimps.
Thomas W, Wed Oct 29 2014, 06:57PM

Indeed i do, however they aren't sold anymore.... How does this look?

Re: Molex connector crimps.
mbd, Wed Oct 29 2014, 10:12PM

Because of the pinball connection, I got my crimpers from Ed at Great Plains Electronics: https://www.greatplainselectronics.com/default.asp. He is a good guy and the prices seem pretty good. Obviously more attuned to pinball than general electronics.

Crimpers are on this page: https://www.greatplainselectronics.com/products.asp?cat=138

I have: 1026-CT, 1028-CT, 3135-CT & 3136-CT. All are good tools. If you are going to be crimping a lot of 0.1" connectors, 3135-CT is your friend but that will set you back USD100.

He also seems to sell the KK-100 series connector kit for USD30 (https://www.greatplainselectronics.com/products.asp?cat=168) but I am not particularly enthusiastic about the crimper in that kit.

When I was commenting on IDC connectors, I was commenting on the 0.1" version of IDC connectors (which is what you were presumably referring to) although my comments also apply to 0.156: connectors. I was not commenting on the ones attached to ribbon cables in PCs. Many pinball manufacturers used IDC 0.1" and 0.156" connectors on their pinball machines (presumably because they were quick to install). These regularly need to be replaced and are normally replaced with crimp style connectors. (Trifurcon style if you are talking 0.156".)

BTW I am not surprised that you cannot get the connectors to work properly if you are using long-nosed pliers. But I do not think that is a fair test.

MBD

Re: Molex connector crimps.
Dr. H., Thu Oct 30 2014, 11:39AM

Good day

a cheaper alternative - . Don't know how good it is.

Cheers

Re: Molex connector crimps.
Thomas W, Thu Oct 30 2014, 02:15PM


Ah okey, that makes sense then :)
Thanks for the help everyone, im gonna go buy the crimps i linked too... while Dr. H' s ones were cheaper, they don't seem to have as much variance as the ones i found.

Thanks,
Thomas

Re: Molex connector crimps.
Thomas W, Fri Oct 31 2014, 12:47PM

Okey, the crimps arrived this morning and i crimped one of those pins before trying to insert it... and it didnt work, it went just the same deph it usually does when i use the pliers. This is rather annoying really. do you think the pins are just the wrong ones.... somehow?

Just gave it a try with a 4 pin housing i have that looked very similar, that worked! :), i guess i just need to order some different plastic housings those 2 pin ones just don't work with the pins i have.

Thanks for all your help, i appreciate it!

Re: Molex connector crimps.
mbd, Fri Oct 31 2014, 04:56PM

Well the part numbers look ok to me but then again I find ordering Molex parts challenging.

I hate to ask this question, but I will anyway. Are you certain that you are inserting the pins the right way round? (I have certainly inserted some the wrong way in the past with varying unacceptable results.)

MBD

Re: Molex connector crimps.
Thomas W, Fri Oct 31 2014, 07:07PM

Yes i am. i managed to get the 4 pin connector working fine, it was the 2 pin one that wasn't.... maybe i just ordered the wrong ones This crimp tool works really well. even though it was admittedly designed for a different connector and markedted under a different section of Molex's products. It covers a much bigger range of crimps and works very well :)

Re: Molex connector crimps.
Linas, Sat Nov 01 2014, 10:22AM



i use this. since it was a bit mad to make connectors by soldering wires to 1mm pitch connectors. This does work much better, up to 2,54mm spacing connectors what i use

Re: Molex connector crimps.
doctor electrons, Sun Nov 02 2014, 02:38PM

What you need is an amp service tool. They are expensive so maybe you could borrow one from a friend!