[Elecraft] OT: Crimping small wires

[EricJ]

I don't usually do that because the wire exiting the APP barrel is still 
just a small strand that flexes easily and can eventually break. It 
gives you a lot more surface area for crimping, but needs strain relief 
to be secure in the long run.

What I do is strip the wire the same length as normal, then fold it back 
over the insulation. I insert the wire and insulation into the barrel 
with the wire down (away from the split in the barrel), then crimp 
normally. This makes a solid electrical connection with the stiffness of 
the wire insulation which also provides more than adequate strain relief.

I've mentioned it here before and some are aghast, but I have maybe a 
dozen connections like that currently in my shack and not one of them 
has ever failed in the 10 years I've been doing it with APPs. But any 
connection where this is necessary is a low voltage, low current DC 
connection so what's it going to hurt? It isn't any worse electrically 
than using a small wire nut which is considered safe enough even for 
house wiring.

Eric
KE6US



On 12/11/2013 9:41 AM, Edward R Cole wrote:
> A little off topic:
>
> I wonder if any of you do what I do when using wires are too small for 
> crimp connectors?  I strip twice as much insulation from the end of 
> the wire and then fold the bare wire over double.  May have to squeeze 
> using small nose pliers to get it doubled tight enough to fit inside 
> the crimp connector.  The crimps hold the undersized wire very well 
> with this procedure.
>
> BTW this works for solid conductor wire, like hookup wire.  Bend the 
> conductor double and there is something for the crimp to hold.
>
> I do not know if this will work with powerpole connectors.  My problem 
> was having too large diameter wire for the powerpole connectors which 
> inhibited proper crimping; solution chose proper size connector for 
> the wire size selected.
>
> 73, Ed - KL7UW
>
> ---------------------
> Date: Wed, 11 Dec 2013 09:00:11 -0500
> From: Don Wilhelm <w3fpr at embarqmail.com>
> To: "Charlie T, K3ICH" <pincon at erols.com>, elecraft at mailman.qth.net
> Subject: Re: [Elecraft] K3 Powerpole Replacement
> Message-ID: <52A86FEB.2070902 at embarqmail.com>
> Content-Type: text/plain; charset=ISO-8859-1; format=flowed
>
> Charlie,
>
> The PowerWerx crimper is good.  Just be certain to fill the cavity with
> wire - for instance the 30 amp connectors are sized for #12 wire - if
> the wire is smaller, it may be loose, so in addition to filling the
> barrel with as many wire strands as I can, I add some solder for extra
> security.
>
> 73,
> Don W3FPR
>
>
>
> 73, Ed - KL7UW
> http://www.kl7uw.com
> dubususa at gmail.com
> "Kits made by KL7UW"
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