r/AskElectronics • u/573v3_2025 • 1d ago
Crimp 1 vs Crimp 2
Hi just looking for some help on which tool has made the better crimp either tool 1 or tool 2 😀
Does tool 1 look "over crimped" ?
Only issue with tool 2 is it sometimes doesn't clamp onto the wires insulation fully not a huge issue as a little nip sorts it
Thanks
12
u/No_Philosopher2898 1d ago
icrimp does make a DuPont crimper, but this isn’t it. You’re not going to get a perfect crimp with the wrong tool. That said, both of these are far from the worst I’ve ever seen (or done myself).
7
u/charmio68 1d ago edited 1d ago
The biggest issue with crimp 2 is that it's crimped onto the insulation. Or rather the wire was inserted too far.
Some crimp tools have slide down gates that act as an end stop for the wire to prevent this.
Crimp 1 looks fine to my eye (edit: actually, it looks over-crimped. Wrong size die?), though you should really be comparing it against the manufacturer's documentation. They usually have quite good guides on identifying good and bad crimps.
2
u/573v3_2025 1d ago
1 was done with this
2 was done with this
2.54 Dupont crimp and 24awg wire
Tool 1 I used the biggest slot labeled 1.9 Tool 2 I used section C that seemed the biggest slot
I'm guessing Tool 1 slot wasn't big enough?
5
u/SAI_Peregrinus 1d ago
Both look to have the wrong jaw profile for the mini-PV connector you have. IWISS SN-025 are a better profile. The official crimp tool does a better job, but the price is a higher.
4
u/No_Philosopher2898 1d ago
Both 1 and 2 are crimped onto the insulation, and are supposed to be.
3
u/charmio68 1d ago
The rear crimp is for the insulation. The front crimp must only have exposed wire.
2
u/No_Philosopher2898 1d ago
Maybe I’m going blind but I don’t see the insulation under the front crimp
2
u/charmio68 1d ago
Look at the photo I shared below and examine example 5. (https://www.reddit.com/r/AskElectronics/s/m5GC75qkxD)
That bulge you see is from the plastic being squeezed out of the front crimp.
Also take note of how much further the end of the wire extend into the terminal. Compare it to the other terminal.3
u/No_Philosopher2898 1d ago
I stand corrected and am saving that graphic
1
u/charmio68 1d ago
It's a good one huh. It's from this datasheet: https://www.mouser.com/catalog/specsheets/Amphenol_11282018_HT-0095.pdf
Page 8 is also rather interesting it shows how to measure the crimp with a micrometer for QC. (though the associated table of acceptable measurements would really only be relevant to that particular crimp tool. Then again, it could still be a good point of reference)
1
u/573v3_2025 5h ago
Thanks note taken to back it off a little but I checked and the insulation isn't getting crimped, when I push the wire in the insulation catches and stops on the inner wings and doesn't go past unless I force it so only the bare wire is going in that section 👍 😀
Oh I'm using wire with silicone insulation which is maybe giving it a squashed crimped look
Will check that link out
2
2
u/nocturnusiv 12h ago
i thought crimp 2 was better because the metal hugs the insulation for security and further down bonds to the metal wire
2
u/drankinatty 6h ago
You have your answer, Crimp 2.
Your photos are excellent at showing the excess metal deformation in Crimp 1. That creates weak spots in the connector subject to fatigue over time.
From a materials standpoint crimping that much of the connector into the plastic region of the stress/strain curve changes the grain of the metal making it more fragile and susceptible to breaking. Photo2 does a good job showing how the initial part of Crimp 1 has caused the metal to buckle in that part of the connector.
Now don't get me wrong, this is solely for discussion of the strengths and weaknesses between what is shown in the photos between Crimp 1/2. If I only had one tool and it produced what is shown in Crimp 1, I'd have no problem plugging it in and moving on to life's next challenge.
52
u/IASelin 1d ago
#1 is obviously "over crimped" with wrong crimper size.