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Crimp Terminals Failing

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Dago

Sun Feb 08 2009, 03:53PM

Registered Member #538 Joined: Sun Feb 18 2007, 08:33PM
Location: Finland
Posts: 181

I've crimped the colored terminals with those plier like crimping tools and never had one fall off. You're supposed to crimp it almost on the inner edge of the connector since the metal inside the plastic is not nearly as wide as the plastic.

mikeselectricstuff

Sun Feb 08 2009, 08:37PM

Registered Member #311 Joined: Sun Mar 12 2006, 08:28PM
Location:
Posts: 253

Unless you have a proper , i.e. ratchet-type crimp tool, solder them.
The only use for the cheap plier type ones is the screw cropper.
To misquote Crocodile Dundee...
That's not a crimp tool. This is a crimp tool

HV Enthusiast

Sun Feb 08 2009, 10:04PM

Registered Member #15 Joined: Thu Feb 02 2006, 01:11PM
Location:
Posts: 3068

They're failing because you didn't use the proper tool. You need a ratcheting crimp tool, however they're expensive (probably $200 bucks for a good one)

Just solder them as everyone else said. No need to remove the plastic.

Just be sure to use a little cloth to wipe up flux once the solder flows.

Steve Conner

Sun Feb 08 2009, 11:05PM

Registered Member #30 Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706

I have the same ratcheting crimp tool as Mike showed, and it only cost about 30 bucks. They had it on sale at Maplin with a big box of assorted terminals.

I've used the cheap plier type before and they seemed worse than useless, but the ratchet tool doesn't mess around. It won't release until you've crimped it tight enough.

TwoSpoons

Mon Feb 09 2009, 02:15AM

Registered Member #1621 Joined: Tue Aug 05 2008, 05:26AM
Location:
Posts: 19

Good tools are always a worthwhile investment. I got a ratchet crimper with changeable dies - I have dies for terminals, BNC, F and RJ-45 connectors.

Hazmatt_(The Underdog)

Tue Feb 10 2009, 08:59AM

Registered Member #135 Joined: Sat Feb 11 2006, 12:06AM
Location: Anywhere is fine
Posts: 1735

I've used the non-ratchet type for years and I usually use the non-insulated crimp die because the insulated crimp die sucks! just plain outright sucks!

If you don't have the actually $130 for a ratchet tool, the simple trick is to strip off 2x the wire, fold and crimp. You will be surprised how much better this works when you have to crimp something in-the-field and God forbid your Portasol runs out.

If you use those 2 bits tandomly, non-insulated die and fold the wire then crimp, you'll be fine from now on.

aonomus

Tue Feb 10 2009, 12:15PM

Registered Member #1497 Joined: Thu May 22 2008, 05:24AM
Location: Toronto, Ontario, Canada
Posts: 801

I don't mean to derail the thread, but since we're on the topic of crimp connectors, how would you guys propose crimping lugs onto welding cable (around 6 to 4/0 gauge?).

Edit: 500th post!

LithiumLord

Tue Feb 10 2009, 03:18PM

Registered Member #1739 Joined: Fri Oct 03 2008, 10:05AM
Location: Moscow, Russia
Posts: 261

Well actually it's a rare and a pretty bad way to fix them by crimping, better solder them as well. In order to do this you'll need a gas torch (in the case you don't have nor really need it in your other works you can just use a gas stove; gasolene and alcohol burners are unrecommended as they heat up things too slowly so heat will travel way more of your cable). Heat up the terminal, apply flux and solder to it just like you do to the bigger copper-tip soldering irons, repeat the same with the wire (the wire needs A LOT OF solder, keep applying it untill you see it's filled perfectly) and finally, having the wire in the terminal, both covered with some solder, apply a large stick of solder (and some flux, of course) while heating them pretty hard so all the initial solder will melt well.

ConKbot of Doom

Tue Feb 10 2009, 03:21PM

Registered Member #509 Joined: Sat Feb 10 2007, 07:02AM
Location:
Posts: 329

aonomus wrote ...

I don't mean to derail the thread, but since we're on the topic of crimp connectors, how would you guys propose crimping lugs onto welding cable (around 6 to 4/0 gauge?).

Edit: 500th post!

Bolt cutter style crimpers, definitely. Ive used some at work for putting ends onto 4 AWG wire, and its so easy, I'd never mess with another method.

I have seen someone make their own from cheap (harbor freight possibly?) bolt cutters and grind a notch into the blades for crimping.

But soldering with a torch works, just clean/sand the terminal afterwards. :) If you have a high power (1000+W) heat gun, you can try that instead of the torch, less likely to overheat/burn stuff.

aonomus

Tue Feb 10 2009, 03:21PM

Registered Member #1497 Joined: Thu May 22 2008, 05:24AM
Location: Toronto, Ontario, Canada
Posts: 801

Well for solder-on lugs, I've used a heat gun on max power to a degree of success and melted a pool of flux-core solder into it (but next time I'm going to have to use a torch + stick, flux core is too small and takes ages).

Just didn't know if there *was* a DIY method to crimp, or if everyone soldered.

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