[sanddrag]

Originally Posted by ToddF

We tackled this problem last summer. Our solution was to purchase one of these:
http://www.harborfreight.com/hydraul...ool-66150.html

We also only use uninsulated terminals, as the hydraulic crimper destroys the plastic insulation. We then use either heat shrink or liquid tape to insulate and strain relieve the wire to terminal connection.

The first terminal I crimped with this thing blew my mind. The terminal and wire are so tightly fused, they are indistinguishable. Even the seam where the terminal overlaps is just gone. Connections made with this tool now have the pull strength of the wire itself.

We use that for our SB50 terminals and 6 gauge ring terminals. It works well and produces a very strong crimp, but the dies are strangely shaped, and cause the terminals to form these "wings" out the sides. I find it too bulky, awkward, and slow for smaller terminals.

We do have a problem with inadequate grip strength in our students. I have some spring clamps students must be able to squeeze and hold all the way before being assigned to any crimping duty. If they can't do it, I offer to let the students take the clamps home to do hand grip exercises to improve their strength.