pic: Recycle Rush Re-design Part 2

[philso]

Not all wire of the same nominal gauge has the same conductor outside diameter. The "wet noodle wire" could be a high-strand count, extra flexible wire such as DLO where the conductor and insulation OD is larger than with the "standard" wire of with the same nominal AWG.

When crimping the "closed" contacts on the wire, if it fits in the hole, it is most likely Okay. With the "open" type shown at the right of the photo linked by Knufire, it would be best to check with the manufacturer of the contact what conductor diameter range (in inches or mm) their contact is meant to work properly with. At the very least, do a bunch of sample crimps, say 5 or more, and do a pull test on each one to ensure that the two "wings" are holding the conductor securely. Of course, you would also want to make sure the wire and contact assembly fit properly in the housing. Just a warning, the larger conductor sizes might cause a ratcheting crimper to jam part way and not be able to complete its cycle.