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Old 11-04-2012, 02:34 AM   #21
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Originally Posted by BadNewsBrewery View Post
P-J,
For those of us that have never soldered a crimped connection, can you offer a few tips / techniques? I've crimped my share of connectors and I've soldered a few connections, but never both. In my mind I'm at a chicken / egg crossroad.
-Kevin
Kevin,

Just as a note. I've seen and been involved in a few rigs over the years where that particular problem has jumped out. The problem really stems from the quality of the crimp tool. A good quality crimper is very expensive and not commonly available. Most buy a common crimper (Lowe/HomeDepot) that does not provide a proper bond between the wire and the crimp on terminal for a high current application. (Note: High Current Application.)

The easiest solution is to place a short length of shrink tube on the wire, place the connector on the wire end and crimp it. Then remove the plastic sleeve from the connector and solder the wire to the connector. Slide the shrink tube in place and shrink it.

Now your connection is sound. No problem..

I hope this makes sense.
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Old 11-04-2012, 02:34 AM   #22
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Be sure the flux you use isn't corrosive. Plumbing flux often is. Rosin core solder is for electrical work.

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Old 11-04-2012, 02:40 AM   #23
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A good quality crimper is very expensive and not commonly available.

This is the crimper I have, and is along the type P-J refers to. Sometimes called a full cycle or ratcheting crimper.

http://www.waytekwire.com/item/405/CRIMPING-TOOL/

With this type of tool you really don't need to solder, but it usually doesn't hurt anything unless you use too much solder and it wicks up the wire, and the application is high vibration.
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Old 11-04-2012, 01:23 PM   #24
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Thanks, team! As I suspected, everyone has their own technique. I'll snag some excess wire and connectors and run a few tests using the methods described above until I get it down pat. I've never had problems on my low draw applications in the past, but if I'm going through the effort of building a system, may as well do it right and double-tap them all.
-Kevin

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Old 11-04-2012, 02:32 PM   #25
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dammit now i have to take mine apart and solder it cause I defiantly used a cheap crimping tool! Thanks all for the safety heads up!

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Old 11-04-2012, 02:44 PM   #26
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A visual inspection should tell you if there is any concern about the connection integrity. If it doesn't look like it's been hot (discoloration) or melted/burnt then there isn't really anything that needs fixing, other than maybe peace of mind.

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Old 11-04-2012, 02:48 PM   #27
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well I am paranoid about safety and to be honest it is not that big of an issue so I might as well find 10 min of my day to just go ahead and do it. I guess you could say "be proactive". That way if for some crazy reason it does catch fire or anything serious I dont have to look back and be like should have soldered it.

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Old 11-05-2012, 08:35 PM   #28
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I wish I was still in the fleet working on helicopters, we had the cream of the crop wiring tools. I probably could have done all my connectors with canon plugs and stuff. That would be sweet!!!

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Old 11-08-2012, 01:02 AM   #29
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Yeah, they're nice but spendy. Just ordered dozen small ones for some instrumentation connections. They're like $25-30 each by the time you get all the tidbits you need to make a complete connector, that's just one half.

On a per-contact basis they weren't as expensive though as the Fischer NIM-CAMAC connectors I bought to make a pair of stereo cables for a certain power amp I have.

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