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nuckolls.bob(at)aeroelect
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 Posted: Tue Feb 17, 2015 10:26 am Post subject: Risks associated with unproven crimp tools . . . |
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Just for grins, I put new terminals on the end of
the test article I received. Voltage drop across
the segment (terminal to terminal) went down from
9+ millivolts to 2.6 millivolts . . . the calculated
drop for the wire itself. In other words, joint resistance
at the terminal interface added no resistance I could
measure . . .
At 10:05 2015-02-17, you wrote:
I was going down that very path, but the fellow at the rather large welding supply house told me it would take $10 per terminal to do the crimps, or for $10 I could by my own tool.
Yes. A few months back we discussed this item from
Harbor Freight . . .
http://tinyurl.com/3tfwav3
I just checked the reviews again and they're good.
Comes with a broad range of die sets that cover
the probable range of needs in our airplanes.
I may pop for one of these and do an article
on it. If you have more than a half-dozen
fat wire terminals to install . . . and you don't
want to solder . . . this is a good value option.
 This particular widget can be bolted to a bench or held in a substantial vise and then operated with an appropriately calibrated Inertial Motivator, in this case a 2 1/2 pound sledge. Works like a charm. I did solder the ring end of the crimps, both to definitively seal and electrically bond the joint. The cable end of the crimp is treated with liquid electrical tape and heat shrink tubing.Â
The operative word here is SOLDER . . . keep in mind
that the design goal calls for 'gas tight' interface
between wire strands and the terminal's wire-trip
barrel.
The minimum-fuss technique calls for a rather well
calibrated mash of wire grip barrel around the strands.
One stroke . . . done right. The other technique
described in my article calls for filling all voids
of the joint with solder and (as necessary) copper
wedges. EITHER technique (or as Glen points out)
a COMBINATION of processes all go to achievement
of the gas-tight design goal . . . lack of
calibration for hammer blows becomes moot.
The terminals I just installed were solder only.
The terminal was snug on the wire so no wedges
were called for.
One caution:  If there is to be a bend in the cable close to the terminal, approximate the bend prior to setting the crimp. The final product will be much easier to use.
Yes . . . 'aircraft' wire is exceedingly picky
for bend allowances. I MUCH prefer welding cable.
Bob . . . [quote][b]
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kjashton(at)vnet.net
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| Posted: Tue Feb 17, 2015 11:11 am Post subject: Risks associated with unproven crimp tools . . . |
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Bob, had any experience soldering terminals to copper-cladded aluminum (CCA) cable? I tried a couple of time using a propane torch with flux added and without flux. The solder just did not want to merge with the materials. Always found it pretty easy with copper cable.
-kent
On Feb 17, 2015, at 1:24 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
[quote] The operative word here is SOLDER . . . keep in mind
that the design goal calls for 'gas tight' interface
between wire strands and the terminal's wire-trip
barrel.
[b]
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