22AWG wires in red terminals

[alpinelakespilot2000]

Whenever I crimp a 22AWG wire into a red terminal I'm always thinking: "not much wire for the terminal to grab onto. I wonder if this thing is going to hold."

Is it good (or not good) practice to strip extra insulation away and double over the wire before inserting it into the terminal and crimping it? It seems like the terminal has more to grab onto doing it this way, but perhaps somewhere there is a prohibition against doing this?

Any thoughts? Thanks.

[Lycosaurus]

Originally Posted by alpinelakespilot2000

...Is it good (or not good) practice to strip extra insulation away and double over the wire before inserting it into the terminal and crimping it? ...

Steve,

I would do a pull test on the connection. If it does not pull out, you are fine, you may want to use heat shrink tubing to provide some support for the wire itself (depending on the application).

Adding extra wire (folding over) will not buy you any additional strength if the pull test passed in the first place.

... those are my thoughts.

[Mike S]

Originally Posted by alpinelakespilot2000

Is it good (or not good) practice to strip extra insulation away and double over the wire before inserting it into the terminal and crimping it? It seems like the terminal has more to grab onto doing it this way, but perhaps somewhere there is a prohibition against doing this?

Any thoughts? Thanks.

I have no idea is the aviation wiring bible is for or against the practice, but I have been doing it for a lot of years, and never had an issue.

As was stated, pull on the finished connection------all of them.

[L.Adamson]

I don't know which crimps you use, but I use the type that have an additional crimp on the wires insulation. I get these at the local FBO.
They are a pink color & see thru.

L.Adamson

[GAHco]

The price for the terminals are reasonable.

You should not need to fold your wires with the correct terminals.

Tech Pages http://www.gen-aircraft-hardware.com...ing&splice.pdf

The cost for the tool (p/n 59824-1) to do the crimp on the wire and the insulation at the same time properly is "Not Cheap" nor will a cheap one do that specific job as well.

[alpinelakespilot2000]

I have Stein's crimper and Stein's pink terminals, so I'm good to go on the quality part. It's pretty hard to make a bad crimp with them, and I have pull tested every single crimp I've made.

My only question was whether there is anything to gain by doubling the wire over before crimping and whether it is even "permissable" to do so.

[gasman]

Originally Posted by alpinelakespilot2000

I have Stein's crimper and Stein's pink terminals, so I'm good to go on the quality part. It's pretty hard to make a bad crimp with them, and I have pull tested every single crimp I've made.

My only question was whether there is anything to gain by doubling the wire over before crimping and whether it is even "permissable" to do so.

I don't think you have a problem with doubling the wire. "PERMISSIBLE" is up to you.

I had to think long and hard before I decided to SOLDER all of my terminals. I use the crimp on connectors but cut off the insulation, insert the wire and give an easy crimp. Then solder, not to wick past the barrel. Then it is covered with a layer of heat shrink for support. Right or wrong, I feel good about my connections and have had no problems.

Having said that, everyone seems to get by just fine with just a good crimp and a pull test.

A bad crimp will create resistance and will change the reading of any gauge that reads resistance.

[ronschreck]

Originally Posted by gasman

I don't think you have a problem with doubling the wire. "PERMISSIBLE" is up to you.

I had to think long and hard before I decided to SOLDER all of my terminals. I use the crimp on connectors but cut off the insulation, insert the wire and give an easy crimp. Then solder, not to wick past the barrel. Then it is covered with a layer of heat shrink for support. Right or wrong, I feel good about my connections and have had no problems.

Having said that, everyone seems to get by just fine with just a good crimp and a pull test.

A bad crimp will create resistance and will change the reading of any gauge that reads resistance.

Stand back! You are about to get buried in replies, all telling you the many reasons you should not have soldered your terminals.

[FredMagare]

Steve,

In regards to doubling over the wire - logically speaking, you're not weakening the wire where the strands enter the insulation. So long as the crimp grips and the barrel holds, I'd say you're ok to do that.

On a side note: I went to great pains to calculate my wire needs and set about purchasing 25ft of 22AWG, 15ft of 20AWG, 22ft of 18AWG, 10ft of 16AWG, etc. For those who are getting ready to wire their aircraft - may I suggest you consolidate your wiring? Why buy 22AWG, 20AWG, and 18AWG in various lengths when 18AWG will handle all of those needs? We don't have so much wire in our aircraft that the extra weight would be even three pounds additional for upsizing a few wire runs. Purchase a couple of spools of 18AWG and 12AWG. That should be satisfactory to carry the majority of your electrical needs with the exception of some of the wiring on the firewall side.

[Mel]

I never use anything smaller than 20 AWG simply for the ease of using it.