Speaker Cable Crimps

[Tenson]

Hi,

I run a small business that makes speakers and I am getting to the point now where the time taken to cut to length, strip and solder all wires is a pain in the ***!

Crimping is obviously an option but I'd still have to strip all wires. Does anybody know of some connectors suitable for internal speaker wiring that cut through the insulation to make contact with the wire when you crimp? You know the sort, where it has some sharp teeth or something on the plug so the wire doesn't need to be stripped.

Thanks in advance!

[ChrisA]

Originally Posted by Tenson

Hi,

I run a small business that makes speakers and I am getting to the point now where the time taken to cut to length, strip and solder all wires is a pain in the ***!

Crimping is obviously an option but I'd still have to strip all wires. Does anybody know of some connectors suitable for internal speaker wiring that cut through the insulation to make contact with the wire when you crimp? You know the sort, where it has some sharp teeth or something on the plug so the wire doesn't need to be stripped.

Thanks in advance!

You mean "IDC" (insulation displacement connectors)? If you Google that term you will find many but I don't see any that are intended for high current. Seems to be mostly used for telephone wire or digital.

But you might try either those automatic wire strippers or make a jig that measures and cuts insulation in one operation.

[hasaudio.co.nz]

Hi, I would go with just getting some automatic wire strippers. Continue to solder the joints because once you just start crimping things, after a while, they can come loose. It may take a little longer, but its worth it to keep the quality level high. Just my 2 cents.

[Rhythm Willie]

I would still recommend crimping then soldering, you are better off having a lifelong reliable connection.

I have tried just crimping, oxidisation etc affects the joint in the longterm, not as mechanically reliable - short term gain, long term pain.

[Tenson]

What do you mean by automatic wire strippers? I've seen machines that measure, cut and strip wire, but they are about £1,000.

[ChrisA]

Originally Posted by Rhythm Willie

I would still recommend crimping then soldering, you are better off having a lifelong reliable connection.

I have tried just crimping, oxidisation etc affects the joint in the longterm, not as mechanically reliable - short term gain, long term pain.

If the crimp oxidizes you did it wrong.

The proper term is "swage" You absolutely need a correct die and tool to swage on a terminal but one done it will outlive a solder joint and is much stronger. The proper swage is "gas tight" so there is no way for air to enter and hence no possibility of corrosion. The metal wire strands and the terminal are welded into a solid mass of metal. That is "literally welded" you do need the right tool and it can't be done with pliers.

While learning to make crimped connections you should pull on a terminal until it fails and make sure it is the wire that breaks, the terminal should never slide off. then in production as a QC check pull EVERY terminal with a certain percentage of the force needed to make it fail. Just tug it by hand and then inspect to make sure the end of the wire still extends past the crimp area. If you are worried about corrosion use tinned wire so the wire and terminal are not dis-similar metals.

If you do make a proper swage soldering in imposable because there is absolutely no way for the solder to get inside between the terminal and the wire as not even gas can get inside the solid lump of fused metal.

In fact that is a good test, if solder can get in , you maded the crimp wrong.

There are automatic wire stripper hand tools that measure, cut and remove the insolation in one step.

Here is one. They come in all prices and quality levels. Google found this one. Showing it just to get across the idea. Best to try a few different brands
http://www.amazon.com/gp/product/B00...PWMD4DTE71REGR

[Tenson]

I've already got a nice hand tool for measuring and stripping wire. That's not what I am after.

The gas tight crimp sounds good. Any links for the kind of tools to do this? Do they all still need the insulation pre-stripping?

[ChrisA]

Originally Posted by Tenson

I've already got a nice hand tool for measuring and stripping wire. That's not what I am after.

The gas tight crimp sounds good. Any links for the kind of tools to do this? Do they all still need the insulation pre-stripping?

Just the common ratchet hand tool. Some have interchangable dies for different terminals, some special purpose. price for the good ones is about $50.

The tool is specific to the type of terminals used. I use those color coded insolated kind of terminals. The color indicats the wire size that fits. The tool crushes the colored insolation and the metal part too, the insolation acts as a strain releif. These terminals and the matching tool have been standardized for year, going back to at least the 1940's

Here is a tool. But any tool with a ratcheting mechanism that will not release until the die is fully closed will work.
http://www.grainger.com/Grainger/items/4CN29

[Black Gate]

Originally Posted by Rhythm Willie

I would still recommend crimping then soldering, you are better off having a lifelong reliable connection.

I have tried just crimping, oxidisation etc affects the joint in the longterm, not as mechanically reliable - short term gain, long term pain.

To prevent oxidisation when crimping, would it be of any help to coat the wire and terminal with Deoxit Gold solution before crimping? Deoxit will coat the metal surfaces with oil to keep oxygen out while maintaining electrical conductivity, true or false?

[hasaudio.co.nz]

Yea I was just meaning a handtool. But you can get machines that do the measuring, cutting and stripping but I dont know what they cost.