How to do Wire Crimping?

Last week, as part of my Electrical Assessment and Practical, we were taught to do wire crimping. Generally, this process is carried out in order to join an electrical wire to a connector at one end. Crimping process has been parts and puzzles in aviation, especially performing modification in various aircraft's wiring circuits. Here is a simple tutorial on how to perform wire crimping ...

What you need ...

Hand Crimping Tool (preferably Ratchet Type)

Terminal Lug
(Ring type)

1) Remove the necessary length of insulation from the wire end
2) Insert the terminal lug into tool barrel of the crimping jaws until the terminal lug barrel rests against the tool stop
3) Insert the prepared wire end into terminal lug barrel
4) Ensure the wire end is flush or not more than 0.03" protruding beyond the terminal lug barrel
5) Squeeze the crimping tool handles firmly while holding the wire end in position
6) Release the crimping tool once the ratchet has been disengaged
7) Examine the wire for proper crimping and secure attachment

Finally, this is my project ... Tata!

Two wires crimped with
Fork type terminal lug at both end
in a heat shrinkable tubing (black color) as
additional insulation and protection against
environmental factors.

Happy Trying :)

p/s: The above procedure is a simplified version of crimping process. It may be differ from that as in the Standard Wiring Practices. Reference should always be made for the proper procedure in the manuals.