nuckolls.bob(at)aeroelect
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 Posted: Sun Feb 19, 2023 6:13 am Post subject: Low cost hydraulic crimp tools |
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| Quote: | | I've got a similar unit; biggest issue for me was that the dies are labeled in metric sizes, with no cross reference. So when I was using it I had to 'guestimate' which die set to use. Looks like the current selection has a cross reference. |
Yeah . . . you noticed too. Suggest you just
ignore the die-size labels.
The short story is to first select a terminal that
is SNUG on your wire strands. If your nearest
best choice is not snug, 'stuff' it with copper
wedges as described in the article on soldering
terminals on FAT wires. Minimizing voids
in the wire grip is critical to success.
Then select a die set that comes to within an
1/8th inch or so of closing. Do the mash.
Do some test crimps (terminals are cheap off
eBay et. als.) Put the terminal in a vice
and pull on the wire. You should not be able
to dislodge it. If you can, repeat with the
original die selection and then add-a-crimp
with the next size down.
The 'too small' die may generate some squish
out at the sides of the wire grip barrel . . .
but it will insure the quality of your grip.
It's okay to sand or file off these little
'wings' of upset copper.
Apply the obligatory double-wall heat shrink
and you're good to go.
I've done about a half dozen test crimps with
the tool I have. I've built a couple of heavy
duty jumper cable sets. By the way, good
cables with #2 or larger wire are pricey . . .
but I found that unit cost can be mitigated
by purchasing a 20 or 25 foot set, cut it in
half and add two sets of clamps to end up with
two 12 foot cables.
I plan to do some more experiments and perhaps
do an article for Kit Planes on the technique.
The finer granularity of sizes is what makes
these latest offerings play well. Ignore the
labels. Optimize occupation of the volume
in the wire grip, eyeball the first-try
die selection, you can always hit it again
with a smaller one, then play tug-o-war with
your experiment.
Bob . . .
Un impeachable logic: George Carlin asked, "If black boxes
survive crashes, why don't they make the whole airplane
out of that stuff?"
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