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.
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.
The solution is to strip twice the amount of the insulation from the wire that would normally be needed.
Fold the exposed bare wire over in order to double the mass of the wire to be crimped.
You can see the wire fills the crimping barrel of the terminal.
A good solid crimp on the terminal.
I like to seal the exposed end of the crimp area with solder.
The remainder of the terminal and wire assembly gets sealed with heat shrink tubing.
