Topic: Proper crimping tool for electrical connectors

[eigenvector]

I have a bunch of wire crimping tools at home, but none of them seem to be the correct tool for crimping the bullet connectors that are used on these bikes.

I intend on redoing (AGAIN!) the wiring harness on my bike but this time using the correct connectors - so the question is, what is the proper tool to use for making the crimp?

I have one of these:
https://images-na.ssl-images-amazon.com/images/I/41JsC-V%2BDyL.jpg

But what I find is that the middle section of the connector is never particularly solid.  It does a good job crimping the back (securing it to the insulation), but the middle is barely deformed leaving the electrical connection poor.

[CycleRanger]

I have a bunch of wire crimping tools at home, but none of them seem to be the correct tool for crimping the bullet connectors that are used on these bikes.

I intend on redoing (AGAIN!) the wiring harness on my bike but this time using the correct connectors - so the question is, what is the proper tool to use for making the crimp?

I have one of these:
https://images-na.ssl-images-amazon.com/images/I/41JsC-V%2BDyL.jpg

But what I find is that the middle section of the connector is never particularly solid.  It does a good job crimping the back (securing it to the insulation), but the middle is barely deformed leaving the electrical connection poor.

http://www.vehicle-wiring-products.eu/product.php/269/ratchet-crimping-tool

These guys sell the same crimper.
http://vintageconnections.com/

[madmtnmotors]

These guys sell the same crimper.
http://vintageconnections.com/

+1

I have the Vintage Connections tool. As long as you are using the connectors designed for it, it works like a champ. Here is a write up I did in another thread:

I highly recommend the proper crimp tool. Here is a copy of my post from another thread, ironically titled "Electrical Connectors":



Strip it. I usually strip about a 1/4" to 5/16". Three-eights is a bit much and not necessary:






Don't forget the insulator! (ask me how I know):




I finally figured out (after about three tries) that it's easier to load the connector in the crimp tool first. Note the stepped jaw. The trailing end has a higher relief so as not to over crimp the insulation:




Ratchet down on it just enough to hold it:






You only need about a 1/4" of insulation extended into the connector. Too much and you get into the part of the crimp that should be catching wire only. The jaws are pretty wide and hard to see inside, so I use my thumbnail as a guide when inserting the wire:






Crimp it!:




Voila' (as opposed to "Viola" which everyone knows is a musical instrument):




And finally, the insulator:




Procedure is the same for other types of connectors, just be sure to use the right insulator. Here we have the insulator for the female bullet:




Load the tool:




Crimp it... crimp it real good... and voila'! (as opposed to "viola" which everyone knows is a musical instrument):




Slide the insulator into place:




Dang! This is how they must of looked when the bike was new!:






Give the wire a tug when you're done. Occasionally I will get a loose crimp, but most of the time it is a result of smaller gauge wire. In those cases I will strip 1/2" of insulation and double the wire back on itself to mimic a heavier gauge wire. These are my go-to connectors for all things automotive. 

[CycleRanger]

Yeah for all the wiring I end up doing I really should buy one of those myself.
Those crimps are soo clean and tidy.

[eigenvector]

Thanks, that's helps - just seeing it in action and knowing what the final product looks like.

[madmtnmotors]

I completely sold on these. The crimps are so tight they are considered "gas tight" (air cannot get in) thus making them very corrosion resistant at the crimp. They even have the flat spade connectors and the plastic multi connector blocks as well. The only time I will use the single crimp connectors anymore is for a temporary repair. 

[Deltarider]

Really good crimping tools are so expensive that I went to a friend who runs a service yard for yachts. For the connectors on my homebuilt E.I. I had to use two different types that would have cost me a fortune. When he explained them, I realised that it is indeed a skill in itself.

[DaveBarbier]

Cycleterminal.com also sells all the connectors and crimpers you need. But they seem to be on vacation until mid August.

If you're doing to whole harness again, I'd recommend good quality wire like GXL and TXL from places like wirebarn.com.


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[eigenvector]

I'll take a look at wirebarn for the wire.

One of the biggest challenges that I had when doing the wire bundle the first time was locating striped wire.  I located some from a Japanese hobby retailer - but there are some wire colors that just aren't available (or perhaps commonly found).

For those I resorted to using shrink tubing on the wire to indicate the stripe.  I'd much prefer the real color.
I'll stick with Vintageconnections if I can - I've bought connectors from them before and they're always decent.

[eigenvector]

There, that was excellent finding a place for striped wire.

Got the big ones on order - bl/w o/w br/bl gr/r etc...

If it pans out and it's good wire - I'll pick up the rest.

[eigenvector]

Well I got in my striped wire from 4rcustoms.

Quick service, they had a ton of options - which is excellent for bikes of this era.
The wire jacket is a little firm - a harder plastic than I used to for wire but that doesn't matter, the wire inside is decent quality.

Good call Cal.

[DaveBarbier]

They mention GXL and TXL wire on their site, is this true for the striped wire?


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[eigenvector]

Doesn't appear to be, at least it isn't listed on the site.

[DaveBarbier]

Ok cool, thanks. Just curious


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