DIY Electrical Crimp Connectors

Crimping tool

Soldered electrical splices and connections have a long tradition for being a reliable method for making reliable connections, but it takes a lot of practice. For the new do-it-yourself electrician or for one who does electrical work occasionally, using crimp connectors is a much better choice. Making a strong crimp connection is a skill that can be easily learned and mastered after a few minutes of practice with the crimp tool and connectors.

Things You'll Need

• Crimp on connector assortment
• Crimping tool
• Assorted size practice wire

Instructions

1. Strip the insulation from the ends of a piece of practice wire. The amount of insulation you need to remove depends on the type and size of the crimp connector. Follow the stripping instructions printed on the instruction sheet that comes with them or the instructions printed on the box. If no stripping instructions came with the connectors, strip just enough insulation from the wire so that the bare wire is visible at the opposite end of the crimp barrel. Be careful to strip enough insulation from the wire so that no insulation enters the crimp barrel. Be careful that no bare copper shows outside the barrel insulation.

2. Strip the insulation using the stripper notch on the crimper tools marked for the gauge wire used. The American Wire Gauge (AWG) sizes indicate the size of the stripper notches. When using this wire gauge, remember that the larger the number the smaller the wire and that the smaller the number the larger the wire. Selecting the proper size notch is vital; if you select a stripper notch too small, you will damage the wire.

3. Slip the crimp connector over the wire. The crimp tool's jaws are color coded to match the color of the crimp connectors. You must match the color on the tool with the color connector.

4. Slip the proper color-coded jaws over the barrel of the crimp connector and squeeze the handles firmly together. The handles should close tightly together if you have selected the right set of jaws. Selecting the right jaws is essential to making a solid crimp connection.

Tips & Warnings

• Crimp-on connectors are designed for use with stranded wire. Do not attempt to use them with a solid copper wire. Stranded wire is flexible and takes the shape of the crimping tools jaw's shape while solid wire remains round. Using a crimp-on connector with a solid wire will produce a weak mechanical connection. Using a crimp-on connector with a solid wire will produce a high resistant electrical connection.

References

• ami.ac: Crimping
• matronics: Anatomy of a Good Solderless Terminal Connection
• cadvision: Electrical - Wire Crimps

Resources

• autoshop101: wire, terminal, and connector repair