Don't scrimp when it comes to the crimp

Solid crimp connections make your power voyager’s electrical system more reliable.

- STEVE D’ANTONIO

I’m often asked by my power voyaging clients, “What do I need to know about making good crimp connections?” Fortunately, not very much.

Material selection

High-quality solderless or “crimp” connectors start with high-quality materials. When a connector is manufactured, a die stamps it repeatedly. This helps to cut and form the metal, but it also work-hardens it. Work-hardened metal is brittle and difficult

to form. As a result, it is not preferable for crimping. Annealing returns the copper to a softer, more malleable state. The barrel portion of a quality connector appears seamless. This is because it is actually welded or brazed together. This means that it can be crimped at any point around the barrel without bursting, while the inside portion of this barrel has serrations that are designed to cut into and grab hold of the wire as the crimp is made. This forms a good mechanical as well as electrical bond. Once the connector is stamped, cut, and annealed, it is then tin-plated, yielding superior corrosion protection.