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post #17 of (permalink) Old 03-05-2016, 09:29 PM
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Location: Kitchener Ontario
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Crimping 101/ Insulated Stakons / Crimpers & Wire Strippers

So I have taken some time and will explain how and why to eliminate the OEM socket and replace with a electrically superior connection.
Follow my post 14 to replace the failed socket.

Note: whenever possible use female for the source of power, in this case the wires from the stator, and male crimps for the load side, in this case the regulator, when connecting a DC circuit, such as providing a lighter plug, use a female for the battery positive source, male to the lighter socket, then reverse the male female for negative ground that is use a male for the frame ground and a female for the negative to the lighter socket negative. This way if ever disconnected it can't be connected reverse polarity because the lighter wiring has one male and one female crimp.

Picture 1 shows a blue crimp using T&B or Channel lock crimper, this is my preferred method. The pink 16 gauge is done with the end "insulated " section of the Channel lock, I don't like this style and many crimpers have the crimp area located like the Greenlee in pic 6, where you have a mechanical disadvantage, unless you can crush pop cans with your bare hands, a very good chance of the crimp failing ( if you can pull the wire out of the crimp , it is failed / insufficient crimp pressure )

pic 4 shows the end of a strped wire between the yellow ( 10 gauge) and blue crimp, notice it is bent in the shape of a hook, between the dark blue and pink is the same wire fully closed, typically I double over the 16 gauge wire and use the 10 gauge crimp for more surface area.

Pic 1 you will notice copper wire extending through the pink crimp, normally it would be slightly shorter but this was done to show no harm in being longer than shorter.The blue butt splice has been crimped by the T&B , the pink was done by the Channellock front crimper. The T&B indentation is my preferred method.

pic 2 shows 14 gauge fully insulated 1/4 inch spade crimps in blue / turquoise , the yellow partially insulated spade crimps is 10 gauge.
pic 7 my preferred wire stripper when panel building on left, my preferred crimper T&B on right
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Last edited by onewizard; 03-06-2016 at 12:08 AM.
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