Over the years, I have just got used to using my same ratcheting style crimp tools, with interchangeable dies, since I can not afford the $2,375 molex would like to charge me for 1 hand crimp tool and 1 die.
My tools get the job done, but I do not know anything different. I probably need to go to expo show where I can have vendors demonstrate - that would sure be great.
So - let's just limit to the standard .1" pin "DUPONT" style crimping terminals + shell headers. I insert my terminal, and often find the terminal will kind of TWIST it's way to one side, and if I do not center that to be exact, I can't stuff it into the shell case correctly since it's a little malformed.
Also, I get completely lost trying to order terminals through MOUSER or digi-key since there are only about 100,000 pages to get lost in, only to find they want to charge $.90 for each terminal - then find another page on the same vendor for the same part number that cost is $.30.
So I order my terminals through eBay, and select "GOLD PLATED". I am going to bring my collection to a jeweler, when I find a good one and pay him to educate me on testing and identifying the quality of gold plating so I can tell if I am being sold food-dye yellow covered terminals, or the real thing. When I do order "GOLD PLATED" it seems the terminals are stamped a little more sturdy, formed different to better fit the wires, than the absolutely cheapest low budget crimp terminals I first started buying.
Anyway. I was wondering if any other experienced crimpers here can give advice, on the various crimp-dies they have used, which terminals they order for which dies - so that I can get a more exacting fit, that would be a little more handi-capable (less fussy to jiggle around in the die and misalign)- if anyone has any comments or advice. I probably need to buy new dies, since I can't possibly see they would be designed for 10,000 crimps without wearing out.
This will not be a lot of help to you, but what the heck.
I spent most of my working life, building prototype equipment, as a contractor, and the rule that was drummed into my head, at times under threat of dismissal, was that for every crimp there is a designed tool, and that is the one you HAD to use. As a contractor, I followed the rules and if a new (to me) crimp was required, I was expected to buy said crimp tool.
When I retired, I had a large tool box full of different crimpers and dies, which I managed to sell to the company I was working for. Got a couple of thousand pounds back. ;D
What I have found over the years, is that some crimps, MUST be done with a specific tool. Many of the standard commercial crimps, though, can often be done very successfully using a couple of tools similar to the attached image. Get ones that have as many different sizes as possible. You might need to use one die for the conductor crimp and a different tool for the cable support. Don't just squeeze till the tool closes. Use your eyes and common sense to determine if it is adequately done.
I have about 6 of those style crimpers - with interchageable dies that I have never actually changed. I know the JST terminals are shorter than DUPONT, so I needed a crimp-tool just for those.
I was just hoping I can find something innovative, that I haven't seen before. I have watched youtube videos, where the person loads a handful of wires into a machine that strips, crimps and ejects as fast as it's loaded, but they did not show the specific details / slow motion of how the machine handles whatever it's doing.
I was thinking of machining my own jig, where I can insert the terminals vertical on my desk, so gravity holds them down, to insert the wire and then crimp using a side-mounted lever (or a motor with a foot-switch).
I try to buy prepinned wires if at all possible. Crimping those by hand is so unpleasant - even pololu's really expensive ones are better than doing it myself.
DrAzzy:
I try to buy prepinned wires if at all possible. Crimping those by hand is so unpleasant - even pololu's really expensive ones are better than doing it myself.
Oh no, I'm so past that. I have many boxes, with shells and terminals. Except the micro JST connectors found on hobby r/c cars and helicopters - I won't do that, I think the wires are like 30 gauge. They're so delicate I need a metal pick to remove them. I avoid using them.
I actually enjoy crimping wires and making harnesses. I would be content making them as a business. I spent alot of time searching for different tools, and haven't discovered anything new, which is why I was considered designing my own new tool, to help others who might be a little handi-incapeable, unsteady with age - could use the help.
