Correct crimping connections for plug wires

JohnJL · 03-02-2008, 02:40 AM

I received a set of wires that needed final trimming and crimping.

I have never done this and haven't found much info on this and other sites.

It looks like from other wires I have the center conductor is folded back on the wire and then the conductor/connector is crimped on to the end to that so that the electrical connection is on the tiny center wire folded back against the sheath. That conductor wire seems to be very delicate, and wound on the outside, tiny fibers on the inside?

These are magnacore 8mm.

Any help on the proper crimping procedure and if this can be accoplished with hand tools? Our host seems not to carry the crimpers?

thanks

stlrj · 03-02-2008, 07:02 AM

You need an ignition cable crimping tool:

http://www.amazon.com/gp/product/B000CPZZQM

Cheers,

Jose'

aturboman · 03-02-2008, 09:07 AM

This is actually the correct German crimper. I finally broke down and bought the correct tool after many years of using "make it work" tools.

This thing is awsome but @ $250 it makes each crimp pretty pricy.

If you were closer I'd offer to do them for you.

Good luck.

stlrj · 03-02-2008, 09:49 AM

$250 for a Beru crimper? Oh yeah, that will be the day.

I doubt you will notice that much of a difference in the crimp that the $11 crimper makes...but then, this is a Porsche site and money does not seem to be an object...silly me.

aturboman · 01:01 PM

I used several other styles for 20 years before biting the bullet.

Believe me it makes a huge differnece in the ease, quality, and most important consistancy of the crimp.

It probably wasn't worth it , but as I get old I'm trying to subscribe to the proper tool for the job theory.

That being said it is very well made and will last several life times.

I'm sure its only a $100 tool; the other $150 is the premium for the Beru name.

Sort of a P car tax for tools, at least I can pass it on to my kids!

stlrj · 03-02-2008, 10:24 AM

Aturboman,

Didn't mean to insult you. Just wanted to let him know that the cheap alternative works fine but requires more attention from the operator.

JohnJL · 03-02-2008, 12:43 PM

Yikes, thats pricy.

Am I correct in understanding the black center wire is folded back against the sheath and then the terminal crimped on? Does the center wire need to be stripped back? I couldnt find any good detailed pics on Magnacore, MSD, or generally on yahoo.

Thanks

aturboman · 01:03 PM

I'm not insulted in the least.

He just asked about the proper tool and technically this is it.

Like everything else there is more than one way to get to the same result.

John, there have been more than one style of ends used over the years.

If you get stuck just send me an e-mail or PM and I'll be more than happy to discuss it further.

snbush67 · snbush67's Garage

JohnJL,

The sheath and insulation has to be stripped back to the core then folded back against the sheath, at the point where the core center wire is folded it should be crimped into the middle point of the connector (so it is pinched in the small crimped portion and the folded back into the larger crimped section along the sheath).
you can test connectivity it with a multimeter, sometimes the black inner core doesn't seem to be conductive but when properly crimped it will be. Do not strip the black center wire.

Let me know if you need a picture and I will go take one. Its hard to explain.

Shane

sig_a · 03-08-2008, 06:59 PM

"It probably wasn't worth it , but as I get old I'm trying to subscribe to the proper tool for the job theory.:

Yes, it's worth it. Being able to afford it's the only reason to hold back. Special tools are fun to buy, and are key to successful DIY Porsche projects. And since I provide my 911's labor, I buy them all the time. One other attraction; all Porsche special tools are high quality in comparison to Made In China cheap crap. Assenmacher is a great resource for special tools.

euro911sc · euro911sc's Garage

Aturboman, can you give us a better pic of this area:

I have a bunch of different quality crimpers and one of them may match. I'm certainly not going to drop the $250. Sounds like we should pool some $'s and pass it around as needed

Kinda like the exhaust gas tester

Best regards,

Michael

Danny_Ocean · 03-08-2008, 08:56 PM

http://www.shopatron.com/product/part_number=35051/424.0

aturboman · 03-09-2008, 07:33 PM

Euro911SC here are the pictures you requested.

This tools is extermely well made and has a nice ratcheting feature so you can't over or under crimp the connector.

I do appreciate the comment Sig A made, he hit the nail on the head.

I guess I should not be ashamed of owning some nice tools when I can afford them.

euro911sc · euro911sc's Garage

hrmnnn... I dont have anything that looks like those crimp shapes.

Thanks for the pics!

best regards,

Michael