Quote:
Originally Posted by Ed Law
We do not solder wires to terminals and we never have problems with them. One thing I do is choose the right size terminal for the wire and invest in the proper crimping tool. Another thing I found out is if I twist the wires first before crimping, it is much more secure because it is much harder for the wire to "slide" out.
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Quote:
Originally Posted by Mr V
#1 thing to do to avoid failed crimps is to not use insulated terminals.
#2 is to use a ratcheting crimper, with a die intended for the wire gauge and uninsulated terminals, they give extra leverage and don't release until the crimp has been completed.
#3 is a little dab of solder on those crimped un-insulated terminals before you cover them with heat shrink.
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We do not solder our connections, use insulated terminals, and don't have a problem with failed crimps.
#2 above is definitely the one biggest thing we have done to ensure crimp quality. We spent under $40 for a high-quality, name brand crimper with the proper die.
We also made sure it was adjusted for the right crimping pressure. The 'right' pressure is when the wire strands actually deform and form a solid mass, with (virtually) no air between strands. We have sectioned our crimps, polished the surface, and examined them under a microscope. Probably overkill, but it was a learning experience for the kids.
And as Ed mentioned, twist the wire strands together - not just so they enter the terminal neatly, but also so you don't get stray strands that can short to other wires.
When stripping, be sure you don't nick any of the strands.
When pull-testing, pull as hard as you can. Pull to destructon during training, so students get a feel for the upper limit...then pull near that for 'production' crimps.
And, of course, use high-quality connectors (name brand, like 3M) of the correct size for the wire, and check them regularly during competition.