Crimping connector contacts

[psycho]

I am looking for some board to cable connectors. I have been using ribbon cables but for only a few wires, these are not feasible. I am looking at the ones like you see in computer cases that connect the LEDs and switches in the case to the motherboard.

Those come in two pieces. The plastic shell, and the actual metal contacts. If you look at this, you can see the contact. This system is great. BUT... The crimping tools are very expensive for these lines of connectors. Has anyone figured out a way to reliably crimp them with a cheap off the shelf tool?

Thanks,
Kevin

[haklesup]

The tool is clearly the way to go for those kind of pinned connectors but if you're real careful, you can usually bend the crimp using a small needle nose plier. You can usually also solder to these without any crimping (or just bending the strain relief part). In either case, it's tedious and I wouldn't want to make a bunch of them at once. Be careful not to bend or get solder on the bent metal part that clips the pin into the socket housing or they will just slip out after all that work.

I am not aware of a low cost crimping tool, have you searched eBay? I see a bunch under $50 but I don't know what size you need. They are not typically very interchangable or universal.

For screw clamped contacts in somewhat larger connector bodies, check out Phoenix Contacts line.

[Dean Huster]

You do have an alternative to buying one of the $140 ratcheting crimp tools with the $80 replaceable dies from AMP.

Start looking through all the electronics specialty tool catalogs, e.g., Jensen, you can find and check out all of their crimpers that are made with the familiar stamped steel construction. You'll find some that will do that "double roll" crimp on the wire. I have three and as I recall, they were under $30 and well-worth the cost.

One is actually an AMP branded tool, but there's no model number on it. It just says "AMP INCORPORATED, HARRISBURG, PA. MFG. IN USA". Well, THERE'S something unusual !! Anyhow, this one does seven different sizes of double-roll crimps, does regular machine screw cutting, and smashes three sizes of the insulated automotive crimp connectors. It also does the round insulation "crimps" on the connector. Mind you, when I find a tool like this, it's used ONLY for the double-roll crimps. I use other non-specialty crimpers to cut my screws to size or smash the automotive connectors so that I don't put undue stress on the crimper joint.

I have another that's an almost exact copy of the above AMP version, but the AMP trade name doens't appear. In fact, there is no identifying marks on it at all. The only difference between the two is a tiny difference in head width and plastic handle color. AMP is yellow, this one is green.

A third one is beefier but but shorter and doesn't have as many crimp "dies". It handles only two double-roll crimp sizes and the three regular automotive crimps. On the handles, it's marked "Prestige 24-7373P". I have it, I don't use it. Its only advantage is that its head is a double thickness so you can crimp longer lengths of connector -- and I haven't found a need for that yet.

Dean

[psycho]

I found one that might work :http://www.harborfreight.com/cpi/ctaf/d ... mber=97420

What do you think? The contacts are for 22 gauge wire and this tool claims to do 22 gauge wire. But is there more to it than that?

Kevin

[haklesup]

No that won't work. That one is for what Dean called Mash up Automotive style connectors. You want one with a more precision tooled jaws which curl the crimp into the wire. This one is little better than a pair of standard pliers (it does have more mechanical advantage though)

For automotive style connectors, I prefer to use the flat stamped cheapo crimper because it shoves a dimple into the connector making for a more reliable connection. If I want real reliability, I'll flow some solder on top.

You can't simplify it to just wire gauge only either, you need to consider the pin style and manufacturer. Some are cross compatible but not all. Exactly what pin/connector are you working with?

Sounds like you need something more like this (though this auction will likely be closed by the time you read this) Search on "Amp Crimper" or "Molex Crimper" The molex ones seem to be a bit more expensive but in many cases are compatible.
http://cgi.ebay.com/AMP-24-20-HAND-CRIM ... 5635b55ad1

Always order more pins than you need so you can rework or change the design if needed. It may be tempting but also avoid crimping 2 wires in the same pin.

[psycho]

These are the contacts: http://portal.fciconnect.com/portal/pag ... reContacts

There is an embedded link in my original post, but it is hard to see. That's why I usually just show links in the "long" format.

btw, I tried emailing the "get tech support" link on the product's page (above) and the mail bounced back to me

-- edit
Radio shack has this: http://www.radioshack.com/product/index ... ab=summary
But I dunno if that will work, either.
--

Kevin

[sofaspud]

I'll throw out this idea...
Instead of having the connector at the end of the wire, have you considered putting it in the middle?
Then you could just use something like insulated spade lugs and not worry about precision crimpers or
itty bitty Molex pins.

[Dean Huster]

Here's the head of the first double-roll crimping tool I found:

http://whiteproducts.com/images/weather ... sts-WP.jpg


Here's some that Jensen Tools (now Stanley) has:

http://www.stanleysupplyservices.com/pr ... px?id=5876
http://www.stanleysupplyservices.com/pr ... pn=450-738


Here's that double-thickness one I mentioned that I have (and didn't use):

http://www.electronictoolbox.com/catalo ... 391104.htm

[flinchy69]

This is a cheapy: http://www.radioshack.com/product/index ... Id=2103683 but I use this on my pinball machines with pretty good results just gotta go slow and steady, not good for a production environment

[psycho]

Thanks! I think I will start by going up to radio shaft and seeing if that one will work.

Kevin

[sofaspud]

One other suggestion. All Electronics has an assortment of matching
headers and connectors with factory-prepped wire leads.