Al's Annual Inspection Thread

It’s rather frustrating and disappointing to have someone of your authority and experience using abstracted anecdotal evidence as part of a technical discussion. Is it fair to say that if this legendary loose wire had been properly crimped that it never would have come loose and 111 would have 4 banners?

Properly executed crimps do not come loose. This is the failure mode of a 6awg KOP terminal when crimped with a $20 hammer crimper:

It supported well over 300lbf of tension before the ring terminal failed. We then sectioned the crimp and found that it was solid metal:

In 10awg the results are equally as impressive with inexpensive equipment. Here I crimped a Harbor Freight 10awg terminal onto some KOP wire with a ~$10 Harbor Freight ratcheting crimper that I spent a little time adjusting (see notched wheel near ratchet mechanism).

I grabbed it with some vise grips…

I tied the wire to my chain fall and stood on a scale, applying more and more weight to the terminal until it broke.

135lbf of tension when the terminal failed where the vise grip was grabbing it.

So, there are some of my own experiments on how robust crimped terminals can be. But, okay, maybe you don’t want to listen to some random guy on the internet. Here is a link to a NASA workmanship standard summary on wire terminals. First sentence:

It was literally someone’s job (probably many peoples’ job) to determine the best practices for wire terminations in systems where failure carries the highest possible penalty. They say crimping is better than soldering. I am inclined to agree with them.

10 Likes