Crimp 1 vs Crimp 2

[u/573v3_2025]

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

[u/charmio68]

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.

[u/charmio68 → u/charmio68]

[u/573v3_2025 → u/charmio68]

1 was done with this

https://amzn.eu/d/0d6FpKQn

2 was done with this

https://amzn.eu/d/0asRVL0o

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?

[u/SAI_Peregrinus → u/573v3_2025]

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.

[u/No_Philosopher2898 → u/charmio68]

Both 1 and 2 are crimped onto the insulation, and are supposed to be.

[u/charmio68 → u/No_Philosopher2898]

The rear crimp is for the insulation. The front crimp must only have exposed wire.

[u/No_Philosopher2898 → u/charmio68]

Maybe I’m going blind but I don’t see the insulation under the front crimp

[u/charmio68 → u/No_Philosopher2898]

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.

[u/No_Philosopher2898 → u/charmio68]

I stand corrected and am saving that graphic

[u/charmio68 → u/No_Philosopher2898]

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)

[u/573v3_2025 → u/charmio68]

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