how to crimp wires without a crimper

How to Crimp Wires Without a Crimper?

Have you ever wondered how some people can crimp wires together with perfect precision? The answer is simple—they use a tool called a wire crimper. Wire crimpers help you to crimp wires together tightly and consistently, so you can make a secure electrical connection and avoid the risk of corrosion and shorting out. So, if you want to learn how to crimp wires, you should know that there are two basic types of crimping tools: manual and hydraulic.

How to Crimp Battery Cable without a Crimper?

An excellent way to fix a bad battery cable is to crimp to the end of the wire using a crimper. But what to do if you don’t have a crimper in your toolbox and crimping needs to be done urgently?

No worries, because you can easily crimp a battery cable without a crimper. A plier is a good solution in this case.

However, you need to keep in mind you will not get the same connection integrity and strength when pliers are used. But the result will be better than putting in bare cable straight into the connector.

Let’s figure out how to crimp the battery cable without a crimper.

How to Crimp Battery Cable without a Crimper – 5 Easy Steps

With basic knowledge of handling different tools, you can effortlessly crimp a battery cable.

Method: Using Pliers

This method is beneficial when there is no crimping tool in your hand, and you need to finish the work quickly.

Required Items:

You can complete the process efficiently by taking assistance from some of the most common tools sitting in your home. Here is the list of the required items.

  • Battery cable end termination: This will help you cover and put the battery cable together.
  • Plier: Choose a classic piece of plier based on the battery cable’s thickness. You need to measure the stripping portion correctly. Otherwise, the battery cable end termination will be too loose or tight. Cutting the cable is necessary for a clean cut.
  • Steel ball or a bolt: You will require this to crimp the battery cable.
  • Bench vise: While crimping, place the cable into the bench vise for secure fitting of the more tractable sleeve. The bench vise will help you seal around the cable tightly. Don’t overtight the cables because metal casing can damage. Connection can’t be made properly.
  • Heat gun: This will provide structural rigidity and a high degree of weather resistance to the crimped joint.
  • Thermoretractable sleeve: Ensure a tight fit between the end terminals and wires.

Step 01: Measure how much wire to strip

Grab the battery cable end terminals and check how much wire to cut. Then use the cutter to cut the cable. Be careful not the cut the wires. Also, while stripping, the cable needs to be stripped evenly.

Don’t use a hacksaw. It will give you uneven and jagged cable ends. Thus, working will be much more challenging.Step 01-Measure how much wire to strip

Step 02: Twist the Cable

Twist the cable until it is tight and slide the ring terminal in place. Here, you don’t need to use any tools. The best thing is to use your hands.

Once twisted, place the cable into the end terminals. Remove any loose ends to improve your cable’s lifespan.Step 02-wist the Cable

Step 03: Slide the Heat Shrink Cover

Use a steel ball or a bolt and a vise to crimp the battery wire. Slide the heat shrink sleeve over the wire first.Step 03-Slide the Heat Shrink Cover

Step 04: Provide a Pull to Test the Cable

First, get the more tractable sleeve. It is an insulating material, making the cable abrasion resistant and environmental protection.

Then, test the terminal with a quick pull. Remember, not to put excessive pressure.Step 04-Provide a Pull to Test the Cable

Step 05: Shrink the Thermoretractable Sleeve Using a Heat Gun

Use a heat gun to shrink the more tractable sleeve till it is snug on the wire.Step 05-Shrink the Thermoretractable Sleeve Using a Heat Gun

Step 06: A Little Comparison

Look at the below image. This will let you understand the difference between the before and after situations.Step 06-A Little Comparison

Warning:

  • If you are not confident enough with this method, we recommend not doing it in tight areas. Also, don’t consider doing it with short wires.
  • Apply the right amount of force. This way, you can crimp instead of cutting the cable and connector.

FAQs

What tools do I need to work with battery cable?

In order to work with a battery cable, you will need a few tools available in your home. You may require a crimping tool to get a precise result. Also, a hammer, plier, or vise is necessary if you don’t have a crimping tool. A cutter or hacksaw is also a must-have tool to strip the wire. Battery cable is a solid and thick material, so a cutter is necessary to cut the cable.

Is it mandatory to measure the cable before stripping battery network cables?

Yes, it is necessary. Otherwise, the battery cable end termination will not fit perfectly, resulting in a poor connection.

What should I use when crimping my wires?

You should use gloves when crimping your wires.

What tools do I need to crimp my wires?

You need a crimping tool, wire cutters, gloves, and a pair of pliers.

Can I use heat tape to crimp my wires?

Yes, you can use heat tape.

How can I make sure my wires stay together?

There are two ways to keep your wires together. The first way is to wrap them with heat tape. The other way is to use electrical tape.

Final Words

Although, it is always better to use a crimping tool to crimp battery cable. But there can be some time when you have other choices except choosing an alternative to a crimping tool. In this case, a plier comes in handy.

Hopefully, now you know how to crimp battery cable without a crimper. Follow the above steps meticulously and have a reliable connection.