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crimp multiple wires into one terminal

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johnbright

Joined: 14 Dec 2011
Posts: 165
Location: Newport News, VA

Posted: Tue May 12, 2020 9:19 am Post subject: crimp multiple wires into one terminal

Hi Bob,



I've seen how you crimp four 22 awg wires into one red (18-22AWG) PIDG terminal and I wonder if this is OK with larger wires and wires of different gages. http://www.aeroelectric.com/articles/multiplewires/multiplewires.html



I'm thinking for example to put a 10 awg and a 4 awg together to save stack height on a contactor or battery stud.



Thanks,

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_________________
John Bright, RV-6A, at FWF, O-360
Z-101 single batt dual alt SDS EM-5-F.
john_s_bright@yahoo.com, Newport News, Va
N1921R links

nuckolls.bob(at)aeroelect
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Posted: Tue May 12, 2020 11:26 am Post subject: crimp multiple wires into one terminal

At 12:19 PM 5/12/2020, you wrote:

  	  Quote: 	
		  --> AeroElectric-List message posted by: "johnbright" <john_s_bright(at)yahoo.com>



 Hi Bob,



 I've seen how you crimp four 22 awg wires into one red (18-22AWG) PIDG terminal and I wonder if this is OK with larger wires and wires of different gages.  http://www.aeroelectric.com/articles/multiplewires/multiplewires.html 



 I'm thinking for example to put a 10 awg and a 4 awg together to save stack height on a contactor or battery stud. 	




   The car-guys do it all the time . . . well . . .

   not exactly 'crimped' but it's common to bring

   two (or more), largely different gage wires into the same

   termination.



   You have two design goals:



   (1) gas-tight connection between conductor

   stranding and the terminal's wire grip barrel.



   (2) insulation support to minimize flexing

   of the stress riser represented by the

   transition from solid (in the grip) to 

   stranded (in the insulation).



   The article I posted about 25 years ago

   is still an excellent approach to your

   mission:



  https://tinyurl.com/ct36xen



   This technique is much less critical of

   wire/terminal/tool sizing. With the stuff-n-

   solder technique, your wire grip can be

   quite tight on stranding. In fact, you

   purposely 'wedge' the stranding until they

   are tight.



   Then fill voids in the grip with solder.

   Step (1) done.



   Finish up with one, perhaps two heat-shrink

   sleeves over the terminal and wire to provide

   some environmental protection and add mechanical

   support. Step (2) done.



   I'd stay with welding cable for the really

   fat wires . . . tefzel is okay for the smaller

   stuff.



   Post some pictures of what you end up with.

   The fat-wire article could stand to be updated

   to include the process you've asked about. 



   By the way, while surfing for a picture

   of a two-wire battery cable, I found what

   appears to be an aftermarket product for

   replacing battery-post terminal-ends with

   . . . who wuda thunk it . . . SOLDERED

   attachement.



 

   Bob . . .

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johnbright

Joined: 14 Dec 2011
Posts: 165
Location: Newport News, VA

Posted: Thu May 14, 2020 7:14 pm Post subject: Re: crimp multiple wires into one terminal

Thanks for the detailed reply Bob.



I'm not far enough along yet but whenever I do get some photos I will post them. Another lister, Jeff Parker, is the one with the issue at present of not having enough stack height on either a battery or contactor stud. Jeff and I have been collaborating on implementing Z-101 onto our respective aircraft with SDS electronic injection and ignition.



Interestingly, Jeff was speaking with a jet aircraft repair technician who mentioned the solder pellet method of attaching a fat wire to a fat lug. This fellow recommended from his experience to crimp after soldering. (Bob responded to this to say don't crimp after soldering, ref  http://forums.matronics.com/viewtopic.php?t=16775418&view=previous)

- The Matronics AeroElectric-List Email Forum -

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_________________
John Bright, RV-6A, at FWF, O-360
Z-101 single batt dual alt SDS EM-5-F.
john_s_bright@yahoo.com, Newport News, Va
N1921R links

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