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HomeTips & GuidesAutomotive Crimp Connectors: DIY automotive wiring harness with them

Automotive Crimp Connectors: DIY automotive wiring harness with them

If you’ve been working on cars for a while, you probably come across several automotive crimp connectors

Manufacturers use crimp connectors to quicken the assembling and disassembling process. 

Without these connectors, dismounting any component from your car would have been a nightmare. 

Lucky for you, you can purchase and install crimp connectors yourself.

Table of Contents

Automotive Crimp Connectors vs Soldering Connection

Crimping uses pressure to attach the contact to the wire. For this process, you’ll need a crimping tool. 

You must squeeze the wire and contact together to form a solid connection. 

It has many benefits compared to soldering. First, crimping is fast and simple because you can do it manually or automatically using a crimping machine.

 Second, a crimped connection has an airtight seal, providing a reliable and long-lasting connection protected from environmental factors like dirt, dust, sand, and moisture.

 Also, crimping is way more consistent because it doesn’t vary according to the skill level and applied method of the technician.

However, one of the downsides of crimping is that you’ll need specific tools according to the contact you plan on using, which could be costly.  

The overall quality of either connection is the most important thing. 

The defects of any connection are the root of electrical problems such as corrosion, shock, and vibration. 

You can battle the sensitivity of either connection by using a backshell. However, keep in mind it will cost you extra.

How To Use Automotive Crimp Connectors

To assemble a wiring harness with automotive crimp connectors, you’ll require some knowledge and the proper tools. 

Tools Required

For this process, you’ll only need a crimping tool. However, remember the type of contacts you use determines how well the crimp works.

 You might need a special crimp tool if you have compound crimpers that require interchangeable dies

Instead of buying a new crimp tool entirely, you can buy the specific tool for that crimp. 

Also, just as a precautionary method, it’s advisable to get a pin extractor in case you need to remove a pin from its plug. 

Not to worry because pin extractors are cheap and are easy to find.

If you don’t have the necessary tools, you can use a pair of pliers to ensure the connections are solid. 

The combination of these two tools is very slow but just as good.

Crimping Tool

Caption: Crimping Tool

Assembling Connectors

The process of assembling any type of connector is the same. 

First, observe the pin to note two available crimping points. 

On the left is where you crimp the pin to the insulation to help relieve strain. The right side, however, is where you crimp the pin to your copper wire.

Don’t forget that there are female and male pins and plugs. It’s important to keep them correctly oriented for proper assembly.

Begin by stripping an eighth of the wire’s insulation at both ends and place your wire in the pin.

While holding both in your arm, place them in your crimp tool and first squeeze the pin into the insulation of your wire, which helps with strain relief.

Remove the pin from your tool and orient it correctly to crimp it onto your wire.

Insert your pin to the plug’s body in the right orientation. Ensure it appears in the right position or snaps, then gently tug it to ensure it doesn’t come loose. 

Repeat the procedure for the rest of the pins, both female and male.

Large AWG Quick Disconnects

These are simply enormous plugs that are capable of handling immensely high currents. 

They are available up to 4/0 AWG and are especially helpful when looking for a reliable high-current disconnect. 

You can use such connectors on huge winches or to connect battery packs on a forklift to their corresponding chargers. 

Such connectors are crimped on the cable’s end and use same-sex connectors. 

Therefore, the negative and positive move in the same direction to eliminate the risk of improper orientation.

Conclusion

There you have it; all you need to know about automotive crimp connectors. Keep in mind that crimping is far more effective and easier compared to soldering.

 For crimping, all you need are the proper tools and necessary knowledge. For all your automotive crimp connector needs, contact Cloom tech.

I am Lillian Yang, having been a sales manager for over 10 years.

I have received many positive reviews from customers. They have praised our excellent service, on-time delivery, and high-quality cable assemblies.

For your projects, please provide cable assembly files/images/smples, etc., so that I can send you a quotation within 24 hours.

Contact me now and let’s get started on building your wire harnesses!

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