How Do You Crimp A Connector Without A Crimper?

Crimp connectors are metal fittings used to connect two wires together to complete an electrical circuit. They consist of a cylindrical sleeve that the stripped wire ends are inserted into. When a special crimping tool is used to apply extreme pressure to the connector, it deforms the metal sleeve around the wires creating a tight mechanical and electrical connection. Connectors that are properly crimped form a secure bond between the wire and connector. This bond remains intact despite vibration, flexing, temperature changes or other environmental factors. Some key reasons crimp connectors are commonly used instead of soldering wires together include:

• Crimping is much faster than soldering.
• Properly crimped connections are more reliable and resistant to failure from vibration or temperature changes.
• Crimped connections can be made without heat or toxic chemicals needed for soldering.
• A wider variety of wire sizes and types can be joined with crimp connectors.

When the right crimping method and tools are used, crimped connectors create durable and highly conductive joints. This makes them an essential hardware component for professional electrical work in many industries.

Gather Materials

Before crimping a wire connector without the proper crimping tool, you will need to gather the necessary materials. These include:

• Wire strippers to remove the insulation from the wires
• Pliers to grip and crimp the wire connectors
• Electrical tape to insulate the connection after crimping
• Connectors that match the gauge of the wires being joined

Wire strippers with both slotted and hole cutter designs will allow you to cleanly remove the insulation without nicking the wire strands. Needle nose and combination pliers with serrated jaws to grip the connector are ideal. Use high quality electrical tape that stretches and conforms to provide a tight seal over the crimped connection.[Source]

Strip the Wire

It’s important to strip the proper amount of insulation from the end of the wire before inserting it into the connector. Most connectors require you to strip 1⁄4 to 1⁄2 inch of insulation. Stripping too much insulation can expose wire strands and lead to shorts or dangerous contact with conductive materials. Stripping too little can result in a loose connection or no contact at all.

To strip the wire, use a wire stripper, utility knife, or sharp blade. Make a ring cut around the insulation without nicking the wire strands underneath. Then pull the insulation off the end of the wire. Check that no stray strands are sticking out and trim if necessary. Refer to the connector specifications for the recommended strip length. For example, WikiHow recommends stripping 1⁄4 inch for most connectors.

Stripping the proper amount of wire helps ensure a solid mechanical and electrical connection when crimping the connector. This prevents connection failure and dangerous conditions down the line.

Insert Wire

Once the insulation has been fully stripped back, the next step is to insert the exposed copper wire completely into the connector or terminal. According to the Cablecraft Crimping Guide, it is essential that the wire be fully inserted so that the crimp engages the bare conductor and not the insulation.[1]

Insert the stripped wire into the connector until it bottoms out. The wire should be visible through the inspection hole in the connector, if there is one. Make sure no bare wire is exposed – all copper should be inside the connector. Do not allow the wire insulation to go under the crimp sleeve. Inserting the wire fully ensures a secure mechanical and electrical connection.

Crimp the Connector

Once the wire is fully inserted into the connector, it’s time to crimp it down securely. Since you don’t have a regular crimping tool, you can use a pair of pliers instead. Choose pliers with a smooth interior surface so they can get a solid grip on the connector without damaging it. Standard combination pliers or long nose pliers both work well for this task.

Position the pliers over the middle of the connector barrel, placing one jaw on each side. Squeeze the handles together tightly to crimp down on the connector and deform the metal around the wire inside. Apply heavy pressure and hold for 5-10 seconds to ensure a tight crimp. The connector should be firmly compressed with no chance of the wire slipping out. Avoid crushing the connector completely flat, however, as you want to maintain the round “barrel” shape.

According to the WikiHow guide “How to Use a Crimping Tool,” using pliers to crimp connectors can form a secure connection when a standard crimping tool is unavailable. However, take care not to damage the soft metal of the connector. Test the crimp afterwards to confirm it is tight and the wire won’t pull free.

Inspect the Crimp

It is critical to visually inspect the crimp to ensure high quality and reliability. There are several key things to look for:

The crimped “ears” should be formed uniformly around the wire. Avoid any crimps with uneven or incomplete ears, as this indicates poor compression. According to Smcontact, compression issues can lead to loss of conductivity.

The crimp should be symmetrically formed all the way around the connector. Look for any defects like cracks or deformations. An asymmetrical crimp can create weak points that may fail under load or vibration.

Make sure the insulation is flush with the crimped barrel. Protruding insulation indicates an incomplete crimp that does not properly secure the wire. According to Wiring Harness News, poor crimp quality can lead to corrosion and connection failure.

Give the wire a firm tug to confirm it is securely retained within the connector. If the wire pulls out at all, the crimp is defective.

Visually comparing the crimp to examples of proper crimps can help identify any issues. Always err on the side of redoing a questionable crimp.

Test the Connection

Once the crimped connection is complete, it’s crucial to test it before using it in a live circuit. This verifies that you’ve made a solid electrical connection between the wire and connector. The best way to test the connection is by using a multimeter to check for continuity.

Set the multimeter to continuity or resistance mode, usually indicated by a sound wave or Ω symbol. Touch the multimeter probes to each end of the crimped connector. The multimeter should beep, flash, or read 0 Ω to indicate a complete circuit with no resistance. This means your crimped connection is good.

If the multimeter doesn’t detect continuity, it likely means you have a poor crimp that is not conducting electricity properly. You’ll need to cut off the connector and repeat the crimp process until achieving a solid connection that passes the continuity test. Checking with a multimeter ensures your crimped connector is safe and reliable before installing it.

Insulate the Connection

After you have crimped your connector and confirmed the integrity of the electrical connection, it is important to insulate the metal parts of the connector to prevent shorts. The best way to do this is by wrapping the connection with electrical tape

You’ll want to use a high-quality electrical tape like 3M Super 33+ Vinyl Electrical Tape. Wrap the tape around the connector and exposed wires, extending it about 1/2″ past the end of the connector. Wrap the tape tightly, with about 50% overlap on each wrap. Go over the connector 2-3 times to create a solid insulation barrier. The adhesive on electrical tape will help seal out moisture and prevent corrosion. Properly taping wire connections helps prevent accidental contact between live wires and other surfaces which could cause dangerous shorts.

Other options besides electrical tape include heat shrink tubing or insulating “boots” that slide over wire connectors. However, for DIY purposes, standard electrical tape is widely available and provides effective insulation and protection for crimped connections.

Safety Tips

When crimping wires without a proper crimping tool, it’s important to take safety precautions to avoid injury or damage. Here are some tips:

Avoid overheating the wire and connector when crimping. Applying too much heat can damage the wire insulation and connector. Only use a controlled flame and heat the connector just enough to melt the solder or adhesive inside (Source).

Disconnect power before working on any electrical connections. Make sure the circuit is completely de-energized to prevent shocks or sparks (Source).

Work in a clean, dry, well-lit area so you can clearly see the connection. Avoid crimping wires in the dark.

Wear safety glasses to protect your eyes from flying bits of metal or solder.

Keep flammable materials away from your work area and have a fire extinguisher on hand.

Let crimped connections cool completely before handling to prevent burns.

Double check wiring before restoring power to ensure proper connections.

Conclusion

In conclusion, while a crimping tool designed specifically for wire terminals provides the best results, it is possible to properly crimp a connector without one. The key is using the right materials, like pliers with a smooth inside surface, and taking care to correctly strip the wire, insert it fully into the connector, tightly crimp the metal all the way around, visually inspect for defects, and test for conductivity. With practice and proper technique, hand crimping can create a solid and dependable connection. However, for frequent electrical work or mission-critical connections, investing in a quality crimping tool is highly recommended.