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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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On 2010-07-03, Karl Townsend wrote:
"Ignoramus31310" wrote in message ... I need to crimp a lot of Molex open barrel terminals for those servo power supplies. I was kind of shocked to find a tool from Molex for $269. But then I found item HWS16166 from http://www.phoenixent.com/ It does a great job. i I've got one that's like a pair of pliers. I've been disapointed. Most crimps are great, then I get one where the wire slides back out of the crimp after a while. I started pulling on the just crimped connecter to test them and it mostly solved the issue. Most of the trouble is with 22 guage and smaller. Have you tried this tool with this fine a wire and checked if they will pull out? Part of the problem is getting terminals designed for the wire gauge. There are usually two or three terminals to fit a given connector body with different wire sizes and requiring a different nest in the crimper. (In the AMP connectors of the DB-25 and similar series, there are two pin sizes -- one with a tiny blue dot, the other with a tiny red dot.) Also -- avoid terminals which have a single 'U' instead of two. The crimper should have separate zones for the two 'U's. The zone closer to the pin crimps on the bare wire to make connection, and the zone closer to the wire insulation end is intended to crimp only onto the insulation to prevent vibration flex right behind the crimp which leads to early failure. Another problem is if the crimper does not have a ratchet to force you to complete the crimp cycle before you relase the terminal. If you can't get terminals and a crimper to precisely fit the 22 ga wire, do what I do: 1) Strip about 2-1/2 times the normal recommended length. 2) Twist the wire tighter as you pull the insulation clear. (Start the strip with the stripper, but finish removing the insulation by hand.) 3) Fold the stripped wire in half so it fills more of the space in the terminal, insert that and crimp. Oh yes -- another thing to consider. These open-sided terminals are made to use on stranded wire -- not solid wire. Avoid solid for this kind of wiring. For the closed tube style with insulation plastic on them (not usually in connector bodies) the size of wire is indicated by the color of the plastic sleeve -- cycling through three colors normally. ga color ---- ----- 26-24 Yellow 22-18 Red 16-14 Blue 12-10 Yellow 8 Red 6 Blue 4 Yellow 2 Red 0 (1-0) Blue 2-0 Yellow 3-0 Red 4-0 Blue The group of three is the most commonly useful size, but I have AMP brand terminals and crimpers (not for sale) for almost all of the sizes listed in my personal collection. (Anything from 8 ga up is hydraulically crimped, the others are manual -- though the common group is also available with a pneumatic crimper for production runs. Good Luck, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
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