With all the bad relay grounds users have been finding. I decided to start a how to for crimping the open barrel type terminals. It’s pretty simple and after you try a few you can get perfect crimps.
My crimper is a Tool Aid type with different dies for different type of terminal crimps. I use this for both open barrel and non-insulated closed barrel terminals. This crimper crimps both the wire and insulation with one operation. You can get some crimpers that will do those two crimps with two separate operations. I bought this crimper on EBay for about $70.
The terminals with correct latch pin for our relay sockets are:
AMP 42100-1 for 14 – 18 AWG wire. Digi-key part number A27935CT-ND
AMP 60253-2 for 12 – 16 AWG wire. Digi-key part number A27937CT-ND. Use these for 12 or 10 AWG.
Put the pin into your crimper and close it just a little to hold it in place.
Strip your wire to the length of the smaller part of the terminal. The second part should crimp over insulation to give the wire more stress relief.
Stick the striped end into the terminal now held in the crimper. You will feel where the insulation will butt up to the correct position.
Close the crimper fully while holding the wire in place.
Note when you install the jaws (dies) in the crimper that the larger gauge crimps are closest to the handle. That makes less work for those large gauge wires.
I also use STRIPMASTER by IDEL wire stripers. Working in tight areas these hole the wire and make great wire strips without nicking wire.
Dave M vin 03572
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