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aerobubba(at)earthlink.ne
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 Posted: Mon Nov 09, 2009 3:59 am Post subject: Was wire size, now crimping heavy wires |
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I would add to Charlie's experience that when I went through this process,
the guy in my local welding shop said he'd do my crimps for $10, or he'd
sell me a crimping die for the same price. It's a self gauging device you
can put on a bench or set on the floor and whack a couple times with a good
sized hammer. (Actually, you can gauge the crimps by ear as well or better
than by sight). Natch, I bought the die and have made a dozen crimps with
it and loaned it out to a couple of my cohorts as well. It's definitely
one of the more cost effective tool investments I've ever made.
A couple thoughts on technique: When set properly, the crimp is gas tight.
Needless to say, the individual strands of wire can't slide over each other
and you might as well have a solid copper bar in the crimp zone. This
makes the cable significantly less flexible adjacent to the crimp,
transitioning back to quite flexible a couple inches out from the terminal
barrel. If you need to make any sharp bends near the end of the installed
cable, it would be beneficial to have another set of hands to pre-bend the
cable as the crimp is being made.
The other thing is that since welding cable is not tinned like the Tefzel
is, after making the crimp I tinned the cut end of the cable for corrosion
proofing. Of course, I put heat shrink on the cable-barrel juncture as
well.
FYI, YMMV, etc, etc...
glen matejcek
aerobubba(at)earthlink.net
| Quote: | Subject: Re: wire size
If you walk into your local welding supply shop & tell 'em you need x
feet of #6 and y crimp-on lugs for the wire with z stud size, then ask
if they know anyone who might rent you a crimper, odds are good that
someone at the counter will go get a crimper out of stock & do it for
you on the spot.
Charlie
James Robinson wrote:
> Hi Bob
> Your solution is OK and doable. I just worry about the weight of the
> wire on the copper tie strip on the breakers. I could figure a
> support for the much more flexible wire.
> I am running a pad mount 20 amp and a belt driven 40 amp alternators.
> Can you make up the wires with ends if I provide the length and
> connector sizes?
> Jim
> James Robinson
> Glasair lll N79R
> Spanish Fork UT U77
>
>
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rjquillin
Joined: 13 May 2007
Posts: 123
Location: KSEE
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| Posted: Mon Nov 09, 2009 8:55 am Post subject: Was wire size, now crimping heavy wires |
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At 03:56 11/9/2009, you wrote:
| Quote: | I would add to Charlie's experience that when I went through this process,
the guy in my local welding shop said he'd do my crimps for $10, or he'd
sell me a crimping die for the same price. It's a self gauging device you
can put on a bench or set on the floor and whack a couple times with a good
sized hammer. (Actually, you can gauge the crimps by ear as well or better
than by sight). Natch, I bought the die and have made a dozen crimps with
it and loaned it out to a couple of my cohorts as well. It's definitely
one of the more cost effective tool investments I've ever made.
<snip>
FYI, YMMV, etc, etc...
glen matejcek
aerobubba(at)earthlink.net |
Not as inexpensive as the $10 pound-on-it crimper, but...
These occasionally go on sale at HF for under $50, and with a 20% off coupon on top of that, for <$40 a very nice tool that crimps from AWG-12 to 00 cables.
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=66150
[img]cid:7.1.0.9.2.20091109083511.149f8348(at)gmail.com.0[/img]
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Eric M. Jones
Joined: 10 Jan 2006
Posts: 565
Location: Massachusetts
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| Posted: Mon Nov 09, 2009 10:43 am Post subject: Re: Was wire size, now crimping heavy wires |
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If you go to Ebay and enter "hammer crimper" there are a bunch of them for little money. I have a hammer crimper and it works like a charm.
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_________________
Eric M. Jones
www.PerihelionDesign.com
113 Brentwood Drive
Southbridge, MA 01550
(508) 764-2072
emjones(at)charter.net |
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berkut13(at)berkut13.com
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| Posted: Mon Nov 09, 2009 3:15 pm Post subject: Was wire size, now crimping heavy wires |
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I have one of these. It works great for crimping some large wire gauges - 8 tons of force, hex crimp, etc. However, the dies that are supplied with it are completely marked incorrectly - at least for the type of terminals we typically use in aviation. The range is on the small size in reality and most of the dies are not usable.
It will, however, crimp standard #4, #6 and #8AWG wire terminals using the dies marked "00" (biggest), "0", and "2" respectfully. It might do #10, but I didn't have any around to try.
So, it's cheap..and it works...just don't expect a correct die set.
James Redmon
Berkut #013/Race 13
www.berkut13.com
[quote] ---
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jbr79r(at)yahoo.com
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| Posted: Mon Nov 09, 2009 3:54 pm Post subject: Was wire size, now crimping heavy wires |
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Thanks everyone for the great response!!!
James Robinson
Glasair lll N79R
Spanish Fork UT U77
From: "berkut13(at)berkut13.com" <berkut13(at)berkut13.com>
To: aeroelectric-list(at)matronics.com
Sent: Mon, November 9, 2009 3:09:25 PM
Subject: Re: Was wire size, now crimping heavy wires
I have one of these. It works great for crimping some large wire gauges - 8 tons of force, hex crimp, etc. However, the dies that are supplied with it are completely marked incorrectly - at least for the type of terminals we typically use in aviation. The range is on the small size in reality and most of the dies are not usable.
It will, however, crimp standard #4, #6 and #8AWG wire terminals using the dies marked "00" (biggest), "0", and "2" respectfully. It might do #10, but I didn't have any around to try.
So, it's cheap..and it works...just don't expect a correct die set.
James Redmon
Berkut #013/Race 13
www.berkut13.com
[quote] ---
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rjquillin
Joined: 13 May 2007
Posts: 123
Location: KSEE
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| Posted: Mon Nov 09, 2009 4:01 pm Post subject: Was wire size, now crimping heavy wires |
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At 15:09 11/9/2009, you wrote:
| Quote: | The range is on the small size in reality and most of the dies are not usable.
So, it's cheap..and it works...just don't expect a correct die set. |
And here I just thought they were marked in metric units <grin>
A bit of labor with a die grinder does wonders.
I don't recall exactly where I got dimensions from, perhaps AMP, but they can be made to work quite well.
Ron Q.
[quote][b]
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longg(at)pjm.com
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| Posted: Tue Nov 10, 2009 7:37 am Post subject: Was wire size, now crimping heavy wires |
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Good ole’ Harbor Freight. What would we do without that 500 billion dollar trade deficit. I bought a pair from Stein (also imported) which doesn’t require a shaving kit full of dies, but does cost a few extra bucks. Convenience worth the money. See their tools page.
Glenn
From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of berkut13(at)berkut13.com
Sent: Monday, November 09, 2009 6:09 PM
To: aeroelectric-list(at)matronics.com
Subject: Re: Was wire size, now crimping heavy wires
I have one of these. It works great for crimping some large wire gauges - 8 tons of force, hex crimp, etc. However, the dies that are supplied with it are completely marked incorrectly - at least for the type of terminals we typically use in aviation. The range is on the small size in reality and most of the dies are not usable.
It will, however, crimp standard #4, #6 and #8AWG wire terminals using the dies marked "00" (biggest), "0", and "2" respectfully. It might do #10, but I didn't have any around to try.
So, it's cheap..and it works...just don't expect a correct die set.
James Redmon
Berkut #013/Race 13
www.berkut13.com
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
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