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Old 11-23-2005, 10:22 AM
  #7  
mglavin
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Default RE: Connector crimpers

The right crimpers for the job are paramount IMO, you'll find many available for the task some better than others. Professionals in this industry use crimpers that cost thousands of dollars there is a HUGE difference...

Special thanks to Simon Van Leeuwen for the effort to compile the following information:

Picked from inventory PN's that can be readily purchased from Digi Key, Electrosonic, Newark, Allied Electronics and be on your doorstep next day. Digi Key is probably the best in the shipping area; they have a next-day flat rate to your door):

REPLACEMENT 0.100" SPACING MALE/FEMALE CONNECTORS

NOTE: These housings, spring contacts, and pins will accommodate up to 20awg and feature a locking detent which means they will only physically separate if you unlock them (nice feature). Will handle 4.5A all day.

Description PN Comments
receptacle 104257-2
crimp spring contact 104480-9 30u" Gold, loose
plug 103653-2
crimp pin 104505-7 30u" Gold, loose

GENERIC 0.100" 3 PIN FEMALE CONNECTORS

NOTE: These were chosen to fit all receivers, so they are not keyed.

Description PN Comments
plug, 3 position 530554-2
crimp spring contact 531224-7 30u" Gold, loose

HEAVY DUTY LARGE SCALE 3 PIN CONNECTORS option #1

NOTE: These, and the following series, are readily available high-performance connectors able to handle in excess of 5A, yet are small and lightweight.

Description PN Comments
Receptacle 43645-0300 3 position (up to 12 pos avail)
crimp spring contact 43030-0009 30u" Gold, 20-24awg, loose
plug 43640-0301 3 position (up to 12 pos avail)
crimp pin 43031-0003 30u" Gold, 20-24awg, loose

HEAVY DUTY LARGE SCALE 3 PIN CONNECTORS option #2

NOTE: Not quite so readily available but are slightly smaller and higher performance. These are liquid proof, and offer detent friction lock mechanisms.

Description PN Comments
Receptacle 52213-0311 3 position (4 pos avail)
crimp spring contact 50148-8100 Phosphor Bronze, 20-22awg, loose
Plug 52266-0311 3 position (4 pos avail)
crimp pin 50147-8100 Phosphor Bronze, 20-22awg, loose

SPECIAL APPLICATION PLUG-AND-PLAY SYSTEMS

Description PN Comments
Plug, 8 position 172063-1
Receptacle, 8 pos 172070-1
Spring contact 170311-1 both housings use same contact


HIGH PERFORMANCE HOOK-UP WIRE NOTE:


Alpha 19/34 (19 strands of 34awg) TEFLON jacketed multi-color lead which is service-rated to 13 amps continuous (single lead, free air @ 30C ambient). TEFLON also offers the least mass of all the available jacket materials for weight critical applications such as F3B/F/J style aircraft. You can cut costs by choosing to buy regular PVC jacketed lead, but the performance specs drop off accordingly (8A max, increased jacket mass, bulkier). You will see a PN for this material as well. The PN's essentially remain the same, except that the color code changes. Replace "RD" with the color of your choice (black-BK, white=WH, etc).

Description PN Comments
Red, 22awg, 19/32 5855RD005 TEFLON jacket, 100ft roll
Red, 22awg, 19/32 1855/19RD005 PVC jacket, 100ft roll


Finally one caveat, an onboard control system is only as good as its weakest link...electrically AND mechanically. The above systems rely on proper crimping procedures (amongst other things) to ensure rated specs and mechanical integrity. Don't fool yourself, improper crimping is just as catastrophic as improper soldering.