How to Crimp Wires

Every aspect of an electrical system is important. If there’s a fault somewhere along the line, then the whole system can fall apart — and that doesn’t just result in electrical problems, but it can also pose a health and safety risk, too. There are many components that’ll lead to a safe and sound system, and one of the most important is correct wire crimping. This offers a reliable and easy alternative to soldering when you’re installing electrical connectors, but only if it’s done correctly.

Secure crimps are essential for reliable electrical connections, ensuring uniform, durable, and safe results for both professional electricians and DIY enthusiasts.

On this page, we’ll run through some handy tips and techniques that’ll help you crimp your wires correctly for a smooth, reliable electrical connection. And don’t forget — if you’re looking for the best crimping tool on the market, then be sure to check out the excellent selection of crimping tools we offer here at Wirefy.

Importance of Proper Wire Crimping Techniques

Good crimping techniques will lead to a mechanically sound connection, which is a crucial part of the electrical installation process. Without it, the connection would be more susceptible to infiltration by gas, liquids, and corrosion. As such, you can think of getting the crimping process correct, including the proper use of a crimp terminal, as a way to ensure the long-term health of your wiring. If you don’t, then you’ll have to redo the system at some point or another — and that’s if you’re lucky. Incorrectly crimped wires can lead to a whole host of issues, including fires.

Choosing The Right Tools For The Job

You can’t expect excellent results if you’re using the wrong tools. As you’ll come to see, there are a host of crimping tools on the market. However, it would be wrong to say that one tool is automatically better than the next — the usefulness of the tool comes down to the job; in other words, what it’s being used for. Features like a built-in ratchet are important for ensuring correct pressure during crimping.

You should make your crimping tool selection based on several factors, including how often you’ll be using the tool and the wire gauge. You’ll find that crimping tools are sized in relation to how much wire gauge they can accept. In addition, you’ll need to look at the terminal you’ll be using since each type is for use with a different crimp type. The durability and reliability provided by hardened steel dies are also crucial. Ultimately, the more information you have about the crimping project you’ll be working on, the easier it’ll be for you to choose the right tool.

If you don’t know where to start when it comes to selecting the right tool, take a look at what the manufacturers of the crimping die and terminal recommend. In many cases, there is a specific sized tool that should be used when crimping with a specific terminal.

You can ensure that you always have the right tool for the job by buying one of Wirefy’s crimping tool sets. Our specialist tools are capable of crimping any terminal type and size, so you’ll always be able to get the job done.

How to Prepare Wires and Wire Insulation for Crimping

The foundations of a great crimp begin with preparation. That starts with, as we mentioned above, having the right tool for the job. The goal with the wire is to achieve a clean cut that doesn’t present any damage to the wire. Remember that the insulation around the wire can vary from one wire to the next, so don’t just reach for the nearest tool — make sure you have the right one. That does double for cable cutters; they might look like they can do the job, but they can’t.

Proper wire insulation stripping is crucial to avoid common mistakes and ensure effective crimping.

The stripping process will have a big influence on the eventual success (or failure) of the crimping process. If you strip it too harshly, then you could lose up to 60% of the wire strands, which in turn will severely impact the carrying capacity of the wire, as well as compromise the strength of the joint connection. If you use the right crimping tool and apply pressure correctly, you’ll achieve a clean cut that has the strength to connect and function well.

Step-By-Step Guide to Crimping Wires

Ready to crimp your wires? Follow these five tips for excellent results.

Step One

Gather all the materials and tools that you’ll need. You’ll typically find that these items include:

• Crimp terminals
• Crimp die
• Wirefy crimp tool
• The correct stranded wire.

The Wirefy crimping tool can accommodate wire gauges from 10 to 6 AWG, ensuring you have the right fit for your project. Additionally, for certain applications, using wire rope is crucial for achieving secure connections, especially when paired with high-quality crimping sleeves.

Once you’ve got your tools and materials, you’ll be ready to move on to step two.

Step Two

The next step is getting the wire. It’s always best to use a wire that has individual strands, rather than a single wire since those types are a little more forgiving. You can see what type of wire is required by looking closely at the requirements of the equipment you’re adding the crimping to.

Step Three

You’ll need to have the right terminal in order to establish a quality crimp connection. There will be various options available to you — some of the things to look for include:

• Does it offer pre-insulation? These terminal types grip the wire using a metal sleeve.
• Does it have plating? These terminals offer an extra level of protection against contact resistance and corrosion.
• Is it a turned pin terminal? These are made from rod materials and allow for the creation of connectors.

Step Four

Grab your Wirefy crimping tool.

Step Five

You’re now ready to crimp the wire.

First, measure the wire and strip the end. Once it’s inside the crimp, you should see around 1 - 2 mm extending from it. From there, trim the insulation off the end of the wire to expose the strands.

Put the wire into the crimp, ensuring that all the wire strands are in. Then, put both the crimp and the wire into your crimping tool. Turn the cycle until it releases. You can then remove the crimp, and check that the wire is tight and secure.

Tips for Achieving a Secure and Reliable Electrical Connection

If you’ve followed the tips above, then you should have a secure and reliable electrical connection. Once you’ve finished the crimping job, be sure to give the wire a slight tug — it should remain firmly in place. Once you’ve finished, you’ll be able to test the electrical connection using a multimeter, test light, and wiring diagram. If the reading matches the power that has been specified for the circuit, then you’ll know that you’ve made the connection correctly.

Looking for quality electrical connectors? Then be sure to check out the excellent range we offer here at Wirefy.

Wire Crimping FAQ's

What tools do I need to crimp electrical wires properly?

To properly crimp electrical wires, you will need a quality wire crimping tool, wire strippers, and the appropriate crimp connectors for your specific wires. Some crimping tools come with interchangeable dies to accommodate different connector sizes, ensuring a secure and precise crimp.
How do I choose the right crimp connector for my wires?

Choosing the right crimp connector depends on the wire gauge and the type of connection required. Ensure the connector matches the wire size and is suitable for the application's electrical load. Common types include butt connectors, ring terminals, and spade connectors, each designed for specific connection needs.
What are the common mistakes to avoid when crimping electrical wires

Common crimping mistakes include using the wrong size connector, not stripping enough insulation from the wire, or applying insufficient pressure during crimping. Always ensure the wire is fully inserted into the connector and the crimp is secure but not over-tightened, which can damage the wire or connector. Double-check the connection by gently tugging on the wire to ensure it is firmly in place.