regarding crimp wire connectors ..
in the marine world, you can get them with shrinkable tubing built right
onto them.
in other words, 'waterproof crimp type wire connectors."

they're about a buck each I think.  Maybe even $ 1.50 each.
West Marine has them.
I also use nylon crimp connectors with an inch of shrinkable tubing ..that
works nicely.

what I found on cheap crimper tools is they just break easily , like at the
pivot pin.
Get the very best one you can find I suggest.
The channel lock one looks great.

Someone mentioned doing a 'pull test' on them ..
good idea.
better it comes apart now and a connector is wasted, than later in the van
somewhere.

scott
www.turbovans.com
----- Original Message -----
From: "David Beierl" <dbeierl@ATTGLOBAL.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, June 14, 2011 7:55 AM
Subject: Re: solderless connectors

> At 02:02 AM 6/14/2011, Troy wrote:
>>Hi folks:
>>
>>I finally decided to buy myself a good pair of ratcheting crimping
>>pliers, and by some of the OEM type connectors, i.e. one that grabs
>>onto the wire itself and then a 2nd wire band that crimps onto the
>>insulator.  I find it far superior to the blue, yellow, red variety
>>sold in auto parts store that tend to work loose or arc and cause
>>all kinds of problems.
>>
>>I bought my ratcheting crimping pliers from vintage connectors:
>>http://vintageconnections.com/
>>
>>This is a great tool that is well worth the asking price--very nice
>>quality and can recommend it.  For when I don't have the right
>>connectors on hand, I also bought the die set for the ubiquitous
>>red, blue, yellow, types mentioned above, . This die stands a chance
>>of working on the cheap connectors from some tests I ran tonight,
>>but will wear your hands out in a hurry.
>
> You'll do yourself no favor using cheap connectors.  If you're not
> wincing at the price of crimp connectors then you're not buying brand
> name ones.  NAPA has good ones in your choice of vinyl insulation or
> for more money aircraft-grade nylon insulation.
>
> The connectors you're talking about (open-barrel crimp terminals with
> separate insulating sleeves) are not IMO intrinsically superior to
> the others, quality for quality.  You can get "regular" crimp
> connectors with metal sleeves that crimp the insulation (but they're
> at the high end).  I'm not certain of this but I *think* that the
> only connectors allowed by the FAA for aircraft work are
> nylon-insulated closed-barrel.  The crucial elements are good quality
> connectors and proper crimps (which are bloody hard to achieve with
> the tools sold at the FLAPS.  I use a Channelock 908 electrician's
> crimping tool
> https://picasaweb.google.com/dbeierl/VanagonMeltedEngineHarness#5482720464174658498
> which costs about $15.  Bought it after my good ratcheting crimper
> got swiped, and after bad experiences with the FLAPS ratchet tool.
>
> AMP, 3M, Molex, Thomas & Betts are all high-quality brands.
>
>
>>Now my question: does anyone know of a source for the OEM connectors
>>mentioned?  Vintage connectors is a good source for metric and
>>service is good. I need a source for AWG.
>
> I'm losing you here.  Dimensions are dimensions - A 6.3 mm spade
> terminal in Japan is a quarter inch here no matter what you call it
> (and anyway they call it 6.2 mm in Germany) - and all their
> connectors are specified to take a range of wire sizes in AWG.  The
> real lack I see is insulating sleeves for their 14-12 AWG spade
> terminals.  Plus of course anything for wire sizes larger than 12 AWG.
>
> Google turns up
>
> http://www.elecdirect.com/default.aspx  - not open-barrel but look
> like a good source in general.
> http://www.alliedelec.com/search/productdetail.aspx?SKU=5120217 -
> this terminal is meant to go in a relay socket.
> http://www.alliedelec.com/search/productdetail.aspx?SKU=5120788 -
> these are only a nickel each, but you have to buy 12,000.  Hurry,
> they only have 26,340 in stock...
>
> Here's the AMP range of open-barrel connectors:
> http://www.te.com/catalog/products/en?q=open+barrel+connectors&s=60
> Molex:
> http://www.molex.com/molex/products/listview.jsp?query=&offset=0&filter=&fs=categoryid%3AQUICKDISCONNECTS&npp=20&sType=z&autoNav=&path=cQUICKDISCONNECTS%23%230%23%23ig~~nf4||4f70656e&channel=Products&key=quick_disconnect&parentKey=solderless_terminals
>
>
>
>
>>The unfortunate part about these connectors is you cannot buy them
>>at most FLAPS.  Why is it that the junk is more readily available--
>>rhetorical question;)
>
> Open-barrel needs fancier tooling *and* is probably technically more
> demanding of the operator to get a good crimp.  And you need separate
> insulation.  It's the normal method for terminals to be inserted in a
> connector housing.  For straight plug-in terminals the closed type is
> generally more convenient in the field.  As to the quality - people
> don't want to pay for good ones, and there are enough different types
> that the cost builds up quickly.
>
> Yours,
> David