Electrical Crimping Pliers

[Runtoeat]

FWIW I had been crimping electrical connections all along with standard "arched" crimping pliers that also have stripping notches. This crimper just sort of squishes the connector by flattening it out. Many times, I have had wires pull out or become loose. A few years ago I found a pair of what I would call "correct" crimping pliers and bought these at a garage sale. There is no comparison between the crimp these pliers provide compared to the ones that just flatten. Here's an example of the "correct" crimpers:

http://www.grainger....ing-Plier-3KH45 These are what I have but there are less expensive versions.

 

The llittle tab on these pliers puts a tremendous crimp on the center of electrical connections which stakes the loose wire and connector together and this connection will not loosen.

[Doug G.]

Link doesn't show anything.

[Roger Lee]

Those aren't very good crimper's for most of our work. Here are some better types. These next ones will help help from damaging the connector. The ratcheting ones I like the best and do a consistent job and easier to use.

 

http://www.aircraft-...arch/search.php

 

http://www.sears.com...4&blockType=G34

 

http://www.greenlee....roduct_id=19312

 

Cheaper ones, but still okay.

 

http://www.ebay.com/...=item58a76668d3

 

http://www.ebay.com/...=item3a7ef0558a

 

http://www.amazon.co...ASIN=B002PI6LU8

[Anticept]

The ratcheting types do not like the bullet connectors in my experience, but work very well for handshake connectors. I have a couple of different kinds of crimpers in my toolbox.

[Runtoeat]

Roger, thanks for the links. My crimper never has failed me but I'll check out the ones you show.

[FlyingMonkey]

What type pliers are correct to use on the bullet type connectors?

[Mike]

the ones Roger shows been using them for years in the garage trade

 

Mike

 

 

What type pliers are correct to use on the bullet type connectors?

[Roger Lee]

Hi Andy,

 

The ones I posted work. I use them for all my electrical connections except for pin style.

[Adam]

Not to open a can of worms... Assuming you know how to solder properly, I also solder wires after they are crimped. Mechanical crimping is good, mechanical crimping with solder after is better (imo).

[Tom Baker]

Not to open a can of worms... Assuming you know how to solder properly, I also solder wires after they are crimped. Mechanical crimping is good, mechanical crimping with solder after is better (imo).

 

Adam, If I remember right from A&P school solder is not preferred for aviation. The solder makes the wire too stiff causing it to break from vibration.

[FlyingMonkey]

Adam, If I remember right from A&P school solder is not preferred for aviation. The solder makes the wire too stiff causing it to break from vibration.

 

The SportAir workshop I took on electrical systems taught that solder is okay if there was plenty of wire support and stress relief for the joint.

[Adam]

Funny how times and thinking changes over the years. 30 years ago when I was in the service I was actually "certified" under microscope in soldering. I worked on missile systems (lots of vibrations after launch) and there were no standard crimps allowed anywhere. Crimp plus solder was what NASA taught me at Marshall Space Flight Center in Huntsville. OF course now my systems are laying around Smithsonian and Marshall in the museum gathering weeds...

[Runtoeat]

Andy, sounds like we should be asking you what's the correct technique for making wire connections with the training you had. Those old missles may be languishing in the weeds but you probable could light them up by hooking up some jumper cables from you car! Seems I recall a movie where some some old NASA guys fired up a decrepit piece of space junk to get back from the moon. Was that "Space Cowboys"? Good thing they had soldered connections!

[Roger Lee]

Nothing wrong with soldered wires. It's just where you put them.

[FlyingMonkey]

Andy, sounds like we should be asking you what's the correct technique for making wire connections with the training you had. Those old missles may be languishing in the weeds but you probable could light them up by hooking up some jumper cables from you car! Seems I recall a movie where some some old NASA guys fired up a decrepit piece of space junk to get back from the moon. Was that "Space Cowboys"? Good thing they had soldered connections!

 

It's funny in light of what Adam just said. In the SportAir workshop they strongly advise *against* crimping and soldering, saying that you get the worst of both worlds and a solder/crimp joint is actually *more* prone to vibration failure. Of course, this is for GA aircraft that have to survive thousands of vibration cycles. The missile systems Adam worked on really only have to survive the vibrations of a single launch cycle. In that environment the added security of crimp and solder might be ideal since there is not enough time for vibration to work its magic.

 

Adam, sounds like we have some stuff in common. The thesis for my Master of Science in Artificial Intelligence involved designing software using genetic algorithms to "teach" aircraft how to autonomously avoid missiles in combat. It was pretty basic and only worked in two dimensions, but it did learn over time to get better at it.

[S3flyer]

Andy -- small world. My thesis was the development of an expert system shell that was used to diagnose/predict failures in the telephone switching network.

[Tom Baker]

Missiles may have lots of vibration, but it is not long term like we hope our aircraft are. I would think with a missle you would want them real secure, and not be worried about long term.

[FlyingMonkey]

Andy -- small world. My thesis was the development of an expert system shell that was used to diagnose/predict failures in the telephone switching network.

 

Cool! Mine was a classifier expert system using genetic algorithms for the search. I structured the program like a min-max differential game. The longer each trial the simulated airplane avoided the missile, the better it scored, with a big bonus for the missile missing completely.

[FastEddieB]

For the most part, my Sky Arrow is well built.

 

But when the rear headset lost a "side", it was a poor solder connection to blame.

 

I was surprised to find the wires just laid on the side of the terminal and soldered. Back in the day, building Heathkits (!), I had always been taught that solder was only to make an electrical connection - never to provide strength to a junction. IOW, through the terminal, wrap, tug, then solder.

 

NOT like this:

 

[Jim]

As long as we're all bitching about connectors, I still can't believe that spade lugs are even allowed for aircraft use. They loosen up with vibration and thermal cycles and just aren't suitable for anything needing more reliability than a washing machine. Just my humble opinion....

[FastEddieB]

As long as we're all bitching about connectors, I still can't believe that spade lugs are even allowed for aircraft use. They loosen up with vibration and thermal cycles and just aren't suitable for anything needing more reliability than a washing machine. Just my humble opinion....

 

You certainly would not want to use them on something as critical as a voltage regulator, now would you?

 

[Doug G.]

Totally agree about the soldering Eddie. I have done both kit bashing and ugly bug construction on lots of ham radio stuff.