[Elecraft] OT: Crimping small wires

Thu Dec 12 01:36:06 EST 2013

It's true !
Very good Phil...fascinating discussion.

 73, F5VJC a Crimper

On 12 December 2013 02:39, Phil Hystad <phystad at mac.com> wrote:

> 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"
> >>>>> ______________________________________________________________
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> >>>>>
> >>>>
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> >>
> >> --
> >> Walter Underwood
> >> wunder at wunderwood.org
> >>
> >>
> >>
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