how to crimp wires without a crimper

No Crimper? No Problem! Here’s How to Crimp Wires Like a Pro

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.

Why crimp wires without a crimper?

You may find yourself in need of crimping wires without a crimper for a variety of reasons. Perhaps you cannot afford a crimper or do not have access to one. Perhaps you find yourself in a sticky circumstance where you need to crimp wires but no crimper is within reach. You could perhaps just choose to avoid the hassle of renting equipment only to get the job done.

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 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 1: 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 1: Measure how much wire to strip

Step 01-Measure how much wire to stripGrab 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.

When embarking upon the endeavor of crimping wires sans crimper, it is of utmost importance to take meticulous care and precision in every step of the process. The initial step, dear reader, involves the acquisition of battery cable end terminals, and then undertaking the weighty task of determining the exact length of wire that necessitates stripping.

Step 2: Twist the Cable

Step 02-wist the Cable

After successfully stripping the cable to the desired length, the next crucial step in the process of crimping wires without a crimper is to deftly twist the cable until it is tightly coiled, and ready for the insertion of the ring terminal. At this stage, it is of paramount importance to note that no tools are required, and one must rely solely on the manual dexterity of their hands.

Once the cable has been expertly twisted and the ring terminal has been deftly slid into place, it is vital to ensure that any loose ends are removed with the utmost care and precision. Neglecting to attend to this crucial step can have far-reaching consequences, as it can dramatically reduce the lifespan of the cable, rendering it susceptible to a myriad of issues and malfunctions.

Therefore, one must remain vigilant and meticulous at every stage of this intricate and multifaceted process, attending to each and every detail with the utmost care and precision, so as to ensure the seamless and flawless completion of this daunting undertaking.

Step 3: Slide the Heat Shrink Cover

Step 03-Slide the Heat Shrink CoverHaving successfully twisted the cable and inserted the ring terminal, the next pivotal step in the process of crimping wires without a crimper is to deftly slide the heat shrink cover over the wire, ensuring that it is positioned securely and snugly in place.

To ensure the optimum level of security and stability, it is advisable to use a steel ball or bolt, along with a vise, to deftly crimp the battery wire. This will serve to further fortify the cable, rendering it impervious to any potential malfunctions or damage.

Thus, one must remain diligent and meticulous at every stage of this intricate and nuanced process, bearing in mind the pivotal importance of every detail, so as to ensure the smooth and flawless completion of this complex and daunting undertaking.

Step 4: Provide a Pull to Test the Cable

Step 04-Provide a Pull to Test the Cable

After deftly crimping the battery wire and sliding the heat shrink cover over it, the next crucial step in the process of crimping wires without a crimper is to obtain a more tractable sleeve, which serves as an insulating material, rendering the cable impervious to abrasion and environmental factors.

Once this vital component has been obtained, the next step is to subject the terminal to a quick and decisive pull test, so as to determine the efficacy of the crimping process. It is important to bear in mind, however, that excessive pressure must be avoided at all costs, so as to prevent any potential damage to the cable or its components.

Therefore, one must remain vigilant and attentive at every stage of this intricate and multifaceted process, attending to every detail with the utmost care and precision, so as to ensure the seamless and flawless completion of this daunting undertaking.

Step 5: Shrink the Thermoretractable Sleeve Using a Heat Gun

Step 05-Shrink the Thermoretractable Sleeve Using a Heat GunAfter successfully conducting the pull test and determining the efficacy of the crimping process, the final step in the process of crimping wires without a crimper is to deftly shrink the thermoretractable sleeve, using a heat gun, until it is snug and securely in place on the wire.

This crucial step is of paramount importance, as it serves to further fortify and protect the cable, rendering it impervious to any potential malfunctions or damage. It is advisable to exercise extreme caution while using the heat gun, ensuring that it is not too close to the cable or too hot, as this can have far-reaching consequences.

Step 6: A Little Comparison

Step 06-A Little ComparisonIt’s a good idea to step back and take stock of the before-and-after after you’ve finished crimping wires without a crimper.

This task can be aided by consulting a visual aid, such as a picture depicting the cable before and after its astonishing metamorphosis. This will provide a concrete illustration of the advantages of the crimping process and serve to further demonstrate its usefulness.

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.

Method 2: Using a knife

In a pinch, you can crimp wires with a knife instead of a dedicated tool, but the results won’t be as exact. To crimp wires with a knife, follow these steps:

  1. To link wires together, you must first expose roughly half an inch of bare wire by stripping the insulation off both ends.
  2. Line up the wires so their bare ends are touching.
  3. A quarter of an inch from one end of each wire, make a shallow incision across them perpendicularly using a sharp knife.
  4. At the point where the wires were cut, bend them in opposite directions to create a right angle.
  5. Knife the wires together such that their strands are intertwined and twisted.
  6. Insulate the joint by wrapping it in electrical tape or heat-shrink tubing.

Method 3: Using a hammer and nail

In an emergency, you can crimp wires using a hammer and a nail. How? Read on!

  1. To link wires together, you must first expose roughly half an inch of bare wire by stripping the insulation off both ends.
  2. Line up the wires so their bare ends are touching.
  3. Put the wires on a flat, sturdy material like a piece of wood.
  4. Put a nail through both wires, end to end, at a distance of about a quarter of an inch.
  5. Tap the nail down with the hammer to squeeze the wires together.
  6. Take out the nail and see whether it still works. If the fit is not satisfactory, try again, this time using additional pressure.
  7. Insulate the joint by wrapping it in electrical tape or heat-shrink tubing.

Method 4: Using a vise or clamp

Wires can be crimped with a vise or clamp. How? Read on!

  1. To link wires together, you must first expose roughly half an inch of bare wire by stripping the insulation off both ends.
  2. Line up the wires so their bare ends are touching.
  3. Secure the wires in the clamp or vice.
  4. Tighten the connections between the wires with pliers.
  5. Insulate the joint by wrapping it in electrical tape or heat-shrink tubing.

Method 5: Using a soldering iron

Using a soldering iron to join two wires together reliably and permanently is an efficient technique. How? Read on!

  1. To link wires together, you must first expose roughly half an inch of bare wire by stripping the insulation off both ends.
  2. Gather the exposed wires into a tight twist.
  3. Apply heat from the soldering iron to the twisted wires to melt the solder and form a secure joint.
  4. Give the link some time to cool down.
  5. Insulate the joint by wrapping it in electrical tape or heat-shrink tubing.

Step-by-step guide on how to crimp wires without a crimper

The following is a step-by-step guide for crimping wires without a crimper using the forceps method:

  1. Remove the insulation from the extremities of the wires to be joined, exposing approximately 1/2 inch of bare wire.
  2. Wrap the exposed wires securely together.
  3. Using a pair of needle-nose pliers, securely compress the twisted wires. Ensure that equal pressure is applied to both wires in order to establish a strong connection.
  4. To insulate the connection, wrap it with electrical tape or heat-shrinkable tubing.

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 times when you have other choices besides 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.