[Elecraft] OT: Crimping small wires

Phil Hystad phystad at mac.com
Wed Dec 11 20:39:28 EST 2013 

My wife claims that ham radio operators only talk about boring subjects like "Antennas" when they are on the air.  I had to show her this latest stream on crimpers to prove to her that life in ham radio is not only an adrenaline rush but informative too.


On Dec 11, 2013, at 5:20 PM, Harlan <hsherriff at reagan.com> wrote:

> I run a calibration lab. We use go-no go gauges to test crimpers. The allowed tolerance for the gauges are three-ten thousands of an inch... yes good crimpers are an accurate instrument... and they should only be used with lugs/wire sizes specified for them
> 
> Sent from my Verizon Wireless 4G LTE DROID
> 
> Walter Underwood <wunder at wunderwood.org> wrote:
> 
>> I agree. The point of a good crimper is to get a controlled force on the joint to create a reliable mechanical-electrical joint. Putting something springy in there, like insulation, is asking for trouble.
>> 
>> wunder
>> K6WRU
>> 
>> On Dec 11, 2013, at 3:48 PM, bill conkling <nr4c at widomaker.com> wrote:
>> 
>>> 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"
>>>>> ______________________________________________________________
>>>>> Elecraft mailing list
>>>>> Home: http://mailman.qth.net/mailman/listinfo/elecraft
>>>>> Help: http://mailman.qth.net/mmfaq.htm
>>>>> Post: mailto:Elecraft at mailman.qth.net
>>>>> 
>>>>> This list hosted by: http://www.qsl.net
>>>>> Please help support this email list: http://www.qsl.net/donate.html
>>>>> 
>>>>> 
>>>> 
>>>> ______________________________________________________________
>>>> Elecraft mailing list
>>>> Home: http://mailman.qth.net/mailman/listinfo/elecraft
>>>> Help: http://mailman.qth.net/mmfaq.htm
>>>> Post: mailto:Elecraft at mailman.qth.net
>>>> 
>>>> This list hosted by: http://www.qsl.net
>>>> Please help support this email list: http://www.qsl.net/donate.html
>>>> 
>>> ______________________________________________________________
>>> Elecraft mailing list
>>> Home: http://mailman.qth.net/mailman/listinfo/elecraft
>>> Help: http://mailman.qth.net/mmfaq.htm
>>> Post: mailto:Elecraft at mailman.qth.net
>>> 
>>> This list hosted by: http://www.qsl.net
>>> Please help support this email list: http://www.qsl.net/donate.html
>> 
>> --
>> Walter Underwood
>> wunder at wunderwood.org
>> 
>> 
>> 
>> ______________________________________________________________
>> Elecraft mailing list
>> Home: http://mailman.qth.net/mailman/listinfo/elecraft
>> Help: http://mailman.qth.net/mmfaq.htm
>> Post: mailto:Elecraft at mailman.qth.net
>> 
>> This list hosted by: http://www.qsl.net
>> Please help support this email list: http://www.qsl.net/donate.html
> ______________________________________________________________
> Elecraft mailing list
> Home: http://mailman.qth.net/mailman/listinfo/elecraft
> Help: http://mailman.qth.net/mmfaq.htm
> Post: mailto:Elecraft at mailman.qth.net
> 
> This list hosted by: http://www.qsl.net
> Please help support this email list: http://www.qsl.net/donate.html

More information about the Elecraft mailing list