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Old 10-02-2009, 09:41 PM   #21
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I'm so going to prove Joe wrong tonight when I get home. The $8 D-sub crimper is great for the .040" contacts.
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Old 10-03-2009, 11:05 AM   #22
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I found I can make pretty decent mechanical crimps with tools I have. It takes a long time, as I have to crimp each leg individually (4 seperate crimps per pin) but it looks almost pro and holds very tightly. I then, for the hell of it, heat the terminal and draw a bit of solder into it. This locks not just the wire to the terminal, but the terminal to its connector as well.

Takes 10x longer than having the proper tool. But works.
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Old 10-03-2009, 11:53 AM   #23
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I wouldn't use the solder if you dont have to. You risk broken wires. The crimp should hold the insulation tightly so as to provide adequate strain relief, but once you get solder up in the wire beyond the crimp, you get a brittle wire with no bend relief and they snap.
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Old 10-03-2009, 12:02 PM   #24
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I understand. I'm using a small amount just to freeze things together.

When the harness is done, I'll run 1/2" band of epoxy on the leads coming from the connectors. It should be pretty strong and secure.

I'm about halfway finished. Got too much other crap to get done. :(
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Old 10-03-2009, 12:17 PM   #25
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cool. you can also slide a half inch piece of heat shrink over that end too.
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Old 10-03-2009, 04:38 PM   #26
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