Re: 6 Gauge Crimper From Bolt Cutters
 

We have been using the same crimp tool from Mcmaster and it has been working fantastically. We crimp it with that tool and then test the connection to make sure it is mechanically sound. Afterwards we hold it in a vice and flow soldering into the connection with a butane torch. Then some heat shrink to keep it clean and protected.

Re: 6 Gauge Crimper From Bolt Cutters
 

We have used this crimper for quite awhile. It has dies for several crimps

http://www.harborfreight.com/hydraul...ool-66150.html

It has worked quite well for us once we figured out what die to use.
It is around $55

Re: 6 Gauge Crimper From Bolt Cutters
 

Mr Forbes grabbed the other end of the wire while I grabbed a screwdriver, put it through the terminal, and pulled really hard. My full body weight was not enough to break it.

Re: 6 Gauge Crimper From Bolt Cutters
 

We could set up a pull test to make sure that the terminals are really staying on. We have a couple hundreds of pounds of weights that we use in our trebuchet.

Re: 6 Gauge Crimper From Bolt Cutters
 

Unless you were hanging entirely from the crimp (feet off of the ground) your full body weight was not applied to it.

Good idea. A 6AWG crimp should be able to support up to 300lbs.

I know I sound like a bit of a nit, but 6AWG crimps literally power your entire robot, any small flaws in the termination will have a negative effect on every mechanism and system in your robot. Test properly to make sure you're doing it well!

In the preseason I tested small gauge wire crimps, with good success. We just got our 6awg crimper on Saturday... so some testing should be in order before the final 6awg wiring is done on the robot. Perhaps tonight.

Re: 6 Gauge Crimper From Bolt Cutters
 

We tested our 'hammer' type 6-awg crimper. It was my, personal, first time using it, and I only made the one test crimp using an average 2lb hammer, without any Thor-like strength or speed. Though the connector was quite warm after I crimped it.

Apologies for terrible cell phone pictures... :(

Crimper:$32ish from McMaster

http://i.imgur.com/DA8xXQB.jpg (linked due to image limit)

Bolted it to a piece of 8020.

http://i.imgur.com/0gVOaC5.jpg (linked due to image limit)

Clamped the end of the wire in a vise.

http://i.imgur.com/hjrjMxO.jpg (linked due to image limit)

Had people stand on the bar (we would up with two guys, 200lbs and 180lbs each)

http://i.imgur.com/k75U4P1.jpg (linked due to image limit)

The ring on the terminal failed, not the crimp! We did math and determined that the connector failed at about 290lbf, close enough to mil-spec IMO.



We then sectioned the crimp, and sanded it, to reveal a SOLID chunk of copper resulting from the crimp. This is why you do not need to solder proper crimps, ever, because there is literally no volume for the solder to occupy. Everything is in good contact, if not welded together.



Then, out of curiosity, we sectioned an AndyMark brand 6awg crimp. The results were less than ideal... you can clearly see un-crimped wires and/or air-gaps between the wire strands.



Even more curiosity ensued and we tried crimping with a vise, with terrible results. No welding, tons of air gaps, a generally terrible crimp. Don't do this. The picture is both sides of the sectioning cut.



Hope this was a little enlightening, and I hope you go test your various wire crimpers.

Re: 6 Gauge Crimper From Bolt Cutters
 

Nope, not at all. Many of us know that a proper crimp is far superior to soldering, and gas-tight. Nice post!