Poll: electrical connector crimpers/dies

"Bill Daniels" bildan@comcast-dot-net wrote in message ...
:
: Soldering is easy to learn and much more secure than crimped terminals.
:
: Bill Daniels
:


That is just not true. The reality is that you do need to have the correct crimping tool, which is the topic of this
thread, and with those correct tools, the connection will be superior to a soldered connection. I solder my connections
because I do not have the correct crimping tools, not because it is more secure...

Dan DeVillers...

I solder my connections because I do not have the correct crimping tools,
not because it is more secure...

Did you have correct crimping tools in the past to verify they are
superior?

"abripl" wrote in message oups.com...
:
: I solder my connections because I do not have the correct crimping tools,
: not because it is more secure...
:
: Did you have correct crimping tools in the past to verify they are
: superior?
:

Yes, in the many (electrical/electronic) companies where I have worked.

".Blueskies." wrote in message
...

"abripl" wrote in message
oups.com...
:
: I solder my connections because I do not have the correct crimping
tools,
: not because it is more secure...
:
: Did you have correct crimping tools in the past to verify they are
: superior?
:

Yes, in the many (electrical/electronic) companies where I have worked.


Excellent point, because there are wear limits and approved methods of
testing connections, both for security and to verify that the correct
crimper was used. When applied correctly, the result is a "cold weld",
similar to that achieved in "wire wrap", rather than a gas tight seal.

I haven't checked in a *long* time, and don't have reference material
currently in my posession; but it stands to reason that any effective
testing of the security of a termination/connection would constitute
destructive testing. Therefore, if one is really dedicated to verifying
that the "secure", one would need to make a number of sample
connections--both before and after the actual production run for the
airplane project--and make all of the appropriate measurements on the
samples.

A partial list of good information sources might include:
Amp (for their terminals and related crimpers)
Burndy (for their terminals and related crimpers)
The Boeing Workmanship Manual
The McDonnell-Douglas Workmanship Manual (presumably out of print)
The ATA Spec. 100 Manual
(There are sure to be government publications as well, but I don't
know the titles)

Alternatively, soldering has been used successfully for many years, but
*requires* that the strain relief extend beyond the farthest point to which
solder may be wicked. This nearly always means larger, heavier, and more
expensive connectors and/or terminal strips.

Therefore, if you are trying to "only add lightness", avoid solder!

Peter

"Peter Dohm" wrote in message
. ..
".Blueskies." wrote in message
...

"abripl" wrote in message
oups.com...
:
: I solder my connections because I do not have the correct crimping
tools,
: not because it is more secure...
:
: Did you have correct crimping tools in the past to verify they are
: superior?
:

Yes, in the many (electrical/electronic) companies where I have worked.


Excellent point, because there are wear limits and approved methods of
testing connections, both for security and to verify that the correct
crimper was used. When applied correctly, the result is a "cold weld",
similar to that achieved in "wire wrap", rather than a gas tight seal.

I haven't checked in a *long* time, and don't have reference material
currently in my posession; but it stands to reason that any effective
testing of the security of a termination/connection would constitute
destructive testing. Therefore, if one is really dedicated to verifying
that the "secure", one would need to make a number of sample
connections--both before and after the actual production run for the
airplane project--and make all of the appropriate measurements on the
samples.

A partial list of good information sources might include:
Amp (for their terminals and related crimpers)
Burndy (for their terminals and related crimpers)
The Boeing Workmanship Manual
The McDonnell-Douglas Workmanship Manual (presumably out of print)
The ATA Spec. 100 Manual
(There are sure to be government publications as well, but I don't
know the titles)

Alternatively, soldering has been used successfully for many years, but
*requires* that the strain relief extend beyond the farthest point to
which
solder may be wicked. This nearly always means larger, heavier, and more
expensive connectors and/or terminal strips.

Therefore, if you are trying to "only add lightness", avoid solder!

Peter


I see, with regret, that I neglected to include my final comment; which is:

I have not been working on airplanes lately; but when I do have to make
connections, I do solder for the same reason and with the same limitations
that .Blueskies already cited.

Peter

Robert Murray wrote:
Either AMP "red & blues" P/N 59250; or Daniels HX4 with Y501 dies. The
Daniels tools are often on eBay, and reasonably priced as pro tools go. The
AMP crimper is harder to find and more expensive. The AMP crimpers are in
my AOG bag, and the Daniels' are in the big toolbox because they can be used
on coax too.

Bob


I use Daniels HX-4 and did so in the service with good results. Like
any other tool it must be inspected from time to time using the correct
GO-NO - GO gauge. As for connectors I prefer cannon plugs with crimp
pins. Again I use Daniels tools for this too.

Dan, U.S. Air Force, retired

"Dan" wrote in message
news:e4EWg.6357$eZ4.5677@dukeread06...
I use Daniels HX-4 and did so in the service with good results. Like
any other tool it must be inspected from time to time using the correct
GO-NO - GO gauge. As for connectors I prefer cannon plugs with crimp
pins. Again I use Daniels tools for this too.

Dan, U.S. Air Force, retired

Yep! Faster and no cold solder joints to chase.
Bob

Robert Murray wrote:
"Dan" wrote in message
news:e4EWg.6357$eZ4.5677@dukeread06...
I use Daniels HX-4 and did so in the service with good results. Like
any other tool it must be inspected from time to time using the correct
GO-NO - GO gauge. As for connectors I prefer cannon plugs with crimp
pins. Again I use Daniels tools for this too.

Dan, U.S. Air Force, retired

Yep! Faster and no cold solder joints to chase.
Bob


You haven't lived until you have had to repair a solder joint in the
middle of a 100 pin cannon plug


Then again, it's a good idea to lock your work away from the geniuses
who want to help. I once spent 16 hours cutting wires to length, marking
them and soldering on end into one of three bulkhead disconnects. Please
note I said I cut the wires to length. The other ends had to go to
various points on an instrument panel. While I was home sound asleep
some genius decided to tidy everything up by cutting everything to one
length. Would anyone venture a guess as to my reaction when I showed up
for my next shift? Go ahead, guess.

Dan, U.S. Air Force, retired

"Dan" wrote in message
news:_8PWg.6620$eZ4.4208@dukeread06...
Robert Murray wrote:
"Dan" wrote in message
news:e4EWg.6357$eZ4.5677@dukeread06...
I use Daniels HX-4 and did so in the service with good results. Like
any other tool it must be inspected from time to time using the correct
GO-NO - GO gauge. As for connectors I prefer cannon plugs with crimp
pins. Again I use Daniels tools for this too.

Dan, U.S. Air Force, retired

Yep! Faster and no cold solder joints to chase.
Bob


You haven't lived until you have had to repair a solder joint in the
middle of a 100 pin cannon plug


Then again, it's a good idea to lock your work away from the geniuses
who want to help. I once spent 16 hours cutting wires to length, marking
them and soldering on end into one of three bulkhead disconnects. Please
note I said I cut the wires to length. The other ends had to go to
various points on an instrument panel. While I was home sound asleep
some genius decided to tidy everything up by cutting everything to one
length. Would anyone venture a guess as to my reaction when I showed up
for my next shift? Go ahead, guess.

Dan, U.S. Air Force, retired

Well, you're out and about. You obviously didn't over react. G

Peter
(Equally mild mannered)

Peter Dohm wrote:
"Dan" wrote in message
news:_8PWg.6620$eZ4.4208@dukeread06...
Robert Murray wrote:
"Dan" wrote in message
news:e4EWg.6357$eZ4.5677@dukeread06...
I use Daniels HX-4 and did so in the service with good results. Like
any other tool it must be inspected from time to time using the correct
GO-NO - GO gauge. As for connectors I prefer cannon plugs with crimp
pins. Again I use Daniels tools for this too.

Dan, U.S. Air Force, retired
Yep! Faster and no cold solder joints to chase.
Bob


You haven't lived until you have had to repair a solder joint in the
middle of a 100 pin cannon plug


Then again, it's a good idea to lock your work away from the geniuses
who want to help. I once spent 16 hours cutting wires to length, marking
them and soldering on end into one of three bulkhead disconnects. Please
note I said I cut the wires to length. The other ends had to go to
various points on an instrument panel. While I was home sound asleep
some genius decided to tidy everything up by cutting everything to one
length. Would anyone venture a guess as to my reaction when I showed up
for my next shift? Go ahead, guess.

Dan, U.S. Air Force, retired

Well, you're out and about. You obviously didn't over react. G

Peter
(Equally mild mannered)


What saved that jerk's life, besides being sent home before I got
in, was he spent the day cutting and marking new wires. I cleaned up the
connectors and started over. Day shift, I was working swings, installed
the other ends and I got to put the instrument panel in the airplane.
It's truly amazing how many circuit breakers can pop at one time The
ADI and HSI each had 50 something pin connectors I got to redo.
Instruments that were supposed to have red lighting had white lighting,
how does one mess up a 3 pin connector? Usually they wanted 2 weeks
notice for a leave request. My shop chief suggested I take a week off
"starting tomorrow." And that, your honour, is why I didn't get life in
Leavenworth.

As an aside crimp connectors aren't dummy proof either. At another
base a decade later a SSgt was happily soldering crimp pins before
inserting them into a cannon plug on a C-130. She had never been taught
to use a crimper and didn't know she was supposed to use one. I was an
avionics shift chief at the time and went out to check on her an hour
before shift change. She had spent several hours working on a 54 pin
connector that should have taken 30 minutes. The look on her face when I
showed her how to use a crimper was priceless.

And that's trained personnel, some of the work I have seen on home
builts makes me cringe.


Dan, U.S. Air Force, retired