Fitting a small wire to a large terminal.

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Sometimes in the world of automotive electrical repair you just don’t have the right sized terminal for a particular application. Here is one of my work arounds when I run into a heavy ring terminal that had a small wire attached to it.

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The terminal on the left fits the wire and the terminal on the right has enough material in the ring portion to be properly tightened without collapsing.

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The solution is to strip twice the amount of the insulation from the wire that would normally be needed.

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Fold the exposed bare wire over in order to double the mass of the wire to be crimped.

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You can see the wire fills the crimping barrel of the terminal.

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A good solid crimp on the terminal.

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I like to seal the exposed end of the crimp area with solder.

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The remainder of the terminal and wire assembly gets sealed with heat shrink tubing.

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