eamarquardt wrote:Actually I think you're better off using solderless connectors and buying a GOOD crimper (not one of the ones that are just glorified wire strippers). It's been my experience that when you solder the wires they get less flexible and sometimes fail at the connection due to movement and vibration. Crimped connections retain more flexibility at the connection and are less prone to failure. You can buy ring terminals, spade terminals, splices, and male and female spade connectors.
X10 on crimping.
Soldering also has the issue of the left over flux. It is corrosive and will slowly eat away at the wire.
The type of crimper to get depends on the crimps too. The store found crimpers are good for a few hundred crimps, then should be replaced. They are also the right type for the crimps with plastic shells. The main problem is under or over crimping. The fancy crimpers make it easy to hit the right spot. I don't worry much. I'll take a slightly over crimped connection and use the cheaper and more generic crimper. I crimp the joint, and then test pull and wiggle the wire. Properly crimped there will be no motion. It will stay put and not pull out. My preference is to use non insulated terminals, then use heat shrink as needed to waterproof them. You can get waterproof terminals with heatshrink, (
http://www.waytekwire.com/products/41/Terminals/), but they cost allot. The thing is you need to get the non insulated terminals online rather than at the store. I've been getting them in bags of 100 from Waytek Wire, $4 to $12 per 100 terminals, not $2 to $6 for 3 to 10 terminals like at the store. Terminals: (
http://www.waytekwire.com/products/1422/Terminals---Connectors/) and Heat Shrink Tubing: (
http://www.waytekwire.com/products/1381/Tubing/). Waytek has all the right tools in their tool pages, but you will blanch at the prices. I just use a GB one that looks almost identical to this one:
http://www.waytekwire.com/item/466/ALL-IN-ONE-CRIMPER/ I got mine from Menards or HomeDespot for about 3X the price. The color coded spots on it will do the plastic shelled terminals, and the half moon ones work for the plain shell less terminals. For a heat gun to shrink the heat shrink tubing, any one will do. I use one made for shrinking the coverings for RC model aircraft. It's a real cheapie that MonoKote still sells 30 years later.
Crimping tool. Not the one I have, but similar:
http://www.amazon.com/Neiko-Solderless- ... mping+tool My handle grips look different.
On this tool, the color coded crimping spots are opposite the hinge joint from the handle and are marked with dots of paint. They color code to the colors of the terminals in the kit. On the handle side of the hinge point there are three crimping spots that have a half circle on one side, and a point that presses into the middle of them on the other. Those are the ones I use for the non-insulated terminals. The terminal kit would be good for throwing in for emergency repairs on the road. Dump the terminals into a heavy weight zip-lock bag to get rid of the space taken up by the plastic box. I prefer terminals made by 3M or MOLEX. They are both engineered well, and not cheap ripoffs.
Wire stripping. Get one like this one:
http://www.amazon.com/Klein-Tools-11063 ... 873&sr=1-5
I have two from RadioShack and one from GB. The GB one is better and has needed less readjustment over the years. I don't think I spent over $25 on any of them.
If you need to crimp battery wires, then a crimper like this is the cheap way:
http://www.amazon.com/Forney-57637-Lug- ... mping+tool You use a hammer to provide the crushing force. I usually use a few strikes and work my way up to tightly crimped. A proper large wire crimper can easily be 20 to 30 times as expensive.
Heat shrink tubing. I use two types, Polyolefin plain, and Polyolefin adhesive lined. I use the adhesive lined stuff for most connections to waterproof them. The plain I use for insulating shields for female quick connect terminals and for connections that may be pulled apart later. I also usually get the highest shrink ratio available. (
http://www.waytekwire.com/products/1381/Tubing/&Material=Polyolefin&Length=48--Stick).
Waytek isn't the cheapest, and has a minimum order size, but with a few different crimp sizes and types, a crimper, some heat shrink sticks, and possibly some wire you may be over the minimum order size.
On crimp terminal style. My absolute favorite are the style with the ears that are folded in by the crimper. They look like this:
They do require a proper crimp tool for use. Also they are the style used in most multi pole connectors. If you want to use multi pole connectors, get the right terminals and crimper for the type you use. For TD/TTT I don't see much use for them, except for Anderson Power Pole connectors. I've been using waterproof Delphi Metri-pack connectors for farm machinery use. Some trailer lights have connectors for terminals to connect right up to them. They should tell you which series of terminals connect to the terminals on their lights.
by hmikey » Mon Mar 18, 2013 1:15 pm 
do not use this style of crimp tool. They are reliant on the operators grip strength to make the crimp and as we all know this varies from person to person but also how long you have been using the tool that day. Operator fatigue plays a big part in the quality of the crimp. 
