How to Crimp Lugs

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Crimping (also known as terminating) is the process of creating a gas-tight connection between a connector (lug) and a wire. There are an array of different lugs that can be connected to wires, but they are all attached to the wire through deformation, known as crimping. Lugs are attached to solid or stranded wires, as well as telephone, coaxial and other kinds of cables A crimping tool is used to install the lug, after the end of the wire has been prepared.

Things You'll Need

  • Utility knife
  • Lug
  • Crimping tool
  • Remove the plastic insulation from the end of the wire by cutting around the perimeter of the cable with a utility knife, and then pulling the insulation off. Cut back enough insulation so that when the wire is pushed in through the cylinder on the end of the lug, it will protrude from the other end of the cylinder no more than one-sixteenth of an inch.

  • Push the barrel end of the lug onto the end of the wire, so that it touches the insulation.

  • Place the lug into the jaws of the crimping tool, positioning it so that the area on the side of the lug where the metal curls over and touches, will be crimped. Make sure that this area on the lug where the metal curls over is on the exposed wire, and not the insulation covering the wire. Then squeeze the handles of the crimping tool together, to crimp the lug to the wire.

  • Release or pull apart the handles of the crimping tool to release it from the lug.

Tips & Warnings

  • If done properly, the lug needs to be crimped to the wire only once for a tight connection. Always follow the crimping tool directions to ensure successful crimping.

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References

  • Photo Credit Utility knife image by Andris Daugovich from Fotolia.com
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