[Elecraft] OT: Crimping small wires

[bill conkling]

Crimping the wire over the insulation doesn't seem too good to me.

I have used a dab of hot melt glue to stabilize the wire at the rear of the PP Plastic.

...bill nr4c

Sent from my Verizon Wireless 4G LTE DROID

EricJ <eric_csuf at hotmail.com> wrote:

>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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>
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