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There is a dizzying array of crimping tools available on digi-key, mouser, and other distributors. But they nearly always just say they're for specific wire gauges, without reference to what type of connector they're meant for--and just today I came up against a problem where a crimping die I'd paid $50 for turned out to not work at all for the terminal I was trying to crimp onto the wire; even using the 6 AWG hole didn't fit (it's 8 AWG wire with an ordinary uninsulated brazed-seam lug). How are you supposed to know which tool to use for which type of crimp?

I'm aware that manufacturers usually list a specific tool to use, but I can't afford to pay $3000 and wait out a ten-week lead time just to get a few terminals crimped onto some wire.

It'd be greatly appreciated--and hopefully of use to others as well--if someone could give a run-down of different types of common crimp connectors and what sort of tool they're intended to be used with.

Hearth
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  • With TLAR...... – DKNguyen Dec 05 '20 at 01:38
  • @DKNguyen Sorry, what's TLAR? – Hearth Dec 05 '20 at 01:38
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    "That looks about right." – DKNguyen Dec 05 '20 at 01:39
  • @DKNguyen I'd prefer to not spend $50 on a crimp die just to find out it doesn't work, though! – Hearth Dec 05 '20 at 01:40
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    And every crimp tool I see does say what type it is meant for. I compare the shape against the official crimper. – DKNguyen Dec 05 '20 at 01:40
  • @DKNguyen The one I used said it was for "6, 8, and 10 AWG wire terminals", but apparently that doesn't include the sort of thick lugs I was using. – Hearth Dec 05 '20 at 01:42
  • Hmmm, yeah don't buy those unless you recognize the shapes used. I learned most of my shapes from looking at Paladin/GreenLee CrimpAll dies. Also helpful are PowerWerx TriCrimp dies. – DKNguyen Dec 05 '20 at 01:43
  • A guide to the shapes is exactly what I'm looking for in an answer to this question; if you can provide one, that would be great. – Hearth Dec 05 '20 at 01:44
  • https://www.digikey.com/catalog/en/partgroup/crimpall-1300-8000-series/22980 https://powerwerx.com/tricrimp-tridies-accessory-die-sets http://www.lashenelectronics.com/p-1370-paladin-die-sets-for-crimpall8000-1300-series.aspx – DKNguyen Dec 05 '20 at 01:45
  • Paladin Tools was much more informative before GreenLee bought them and stripped away all the info. – DKNguyen Dec 05 '20 at 01:47
  • https://ae01.alicdn.com/kf/HTB1MbD9MVXXXXaFXVXXq6xXFXXXf/1pcs-Special-Crimping-Dies-Jaw-Crimp-Die-Replaceable-crimping-die-sets-for-Ferrules-Crimper-Crimping-Tool.jpg – DKNguyen Dec 05 '20 at 01:50
  • I'm starting to think I just need to get one of these crimpall tools and I'll be set! – Hearth Dec 05 '20 at 01:51
  • I avoid single die crimpers in general. Note that the dies aren't necessarily interchangeable between handles of different brands. At >10AWG you tend to need different crimpers for welding cable. The ones I linked max out around 10AWG if not 12AWG. – DKNguyen Dec 05 '20 at 01:52
  • Yeah, the one I have has interchangeable dies, but it's an Aven Tools brand one and doesn't seem compatible with any of the other brands' crimp dies that I've seen. – Hearth Dec 05 '20 at 01:58

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This is not for professional use cases, but I use pliers in the DIY situation. Either tiny little ones, or the really big 10" ones. I form the metal onto the wire just sufficiently enough to retain it. I then flux and solder it on with an appropriately sized iron.

Whilst perhaps not approved for aeronautical/military use, and slow, the advantage is that I can 'crimp' a large range of terminals with common general purpose tools.

Paul Uszak
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  • I've done this before as well, though some of the connectors I've been working with need quite a lot of force to crimp; battery lugs made of approximately 2mm thick copper are *not* easily crimped with hand pliers! Pliers are pretty good, with careful use, for open-barrel contacts, though. – Hearth Jan 01 '21 at 15:44
  • @Hearth Absolutely. You can also use [water pump pliers](https://cdn.aws.toolstation.com/images/141020-UK/800/49029.jpg) or a vice. And you can go to a blow torch for the big stuff. Just use a little delicacy. – Paul Uszak Jan 01 '21 at 16:15