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Dec 31, 2022 20:53:30 GMT
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I'm fitting a 1.8 to my car, ive redone all the engine bay wiring loom and i have bought a speeduino seafox for it. Now thinking it would be a simple step making the ecu plug up, I'm haveing massive problems crimping the molex connectors. They are deforming, and one side of the cenector is braking off. I am using 32's wire, maybe its a little big but when i have tried with all sorts of other wire it just dosnt work either. the crimp I'm using is this one and people on the speeduino forum say thats the size to use. I can crimp 32;s into dupont conectors with fairly good qualitly. I have no idea what to do, has anyone had this type of problem who maybe is into electronics? thanks |
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16grit
Part of things
Posts: 213
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Dec 31, 2022 23:34:15 GMT
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Are you using the tiny (3mm c-c?) Molex MicroFit connectors? If so then cable wise I have found that 0.5mm/sq really is about the limit. Even then I find that I need to try a good % a second time, but with that size wire they don't distort, but I might not get a good distance between inner and insulation in the crimp etc. on the first try.   |
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thats them, but even with really thin wire it distorts,, what tool are you using?
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16grit
Part of things
Posts: 213
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Here's a bit of info on how I've made this work, hopefully this might assist anyone else looking to crimp these little blighters. Obviously not the only way or tools to use but this is what works for me.
Wire in auto-stripper
remove insulation
twist and trim
place cable in crimped end, use your fingernails or anything handy to maybe put a little starting bend on the insulation crimp so it will sit in the tool nicely
I have a few crimping tools but this one will work with these. If you have one with an (up to) 0.5 two-size crimp (insulation / wire) that should work also
Carefully place in the 0.5 slot, insulation crimp to left, wire crimp to right. Depending on the slots you have on your tool you may want to experiment a little bit and try and find the slot on your tool that is giving the best balance between crimping both the insulation and wire side with as little distortion etc. as possible. Getting it placed in the tool is of course the fiddly bit as you're balancing the weight of the wire with the thing pulling out of the crimper but try and line it up on the right side of the crimper so that the smaller diameter part of the crimp that is going to crimp the wire is at the right spot
Fully squeeze home when you are happy and remove (it shouldn't really require that much effort to pull out
Good luck with it
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Last Edit: Jan 1, 2023 11:47:43 GMT by 16grit
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just tried exactly what you say, and itstarts to fold the terminal around, then when they meet in the middle, they just sit there, and as the crimp goes up, it pushes the arms down and off.
thats in the 0.5 slot and on my tool is says sn-28b for non-insulated tabs and receptacles
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16grit
Part of things
Posts: 213
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Could be a few things I guess, wire size (in my pics that 0.5mm SQUARED) not 0.5 diameter, or maybe the (Chinese, like these all are) tool is not quite right in some way??
Can understand the frustration!
Post up a photie or two if you think that might help anyonw reading to diagnose??
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messing with it now, it looks like its the thickness of my wire, i tried cutting the strands down to 5-6 and where the strain reliefe is using that to catch the other wires, and its working a lot better.
I don't understand why they use this stupid terminal type, as i say itll crimp fine on a dupont connector, shame as the pitch is slightly different or id got hat way.
I'm not sure ill 100% get reliability out of this, not sure what to do.
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16grit
Part of things
Posts: 213
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messing with it now, it looks like its the thickness of my wire....not sure what to do. I'd be inclined to buy a metre or two of 0.5mm/sq wire, get your connectors all populated and sorted with short 'tails', and then get some open barrel (heat shrink type?) connectors and connect up to the larger wire you already have to run all your other connections, should be fairly cheap that way?? |
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Last Edit: Jan 1, 2023 14:07:23 GMT by 16grit
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you can buy the wires precrimped, and i had thought about that but then with say the crank sensor wires, i don't know if the joint can add noise, or anything like that. so I'm having a little play with my 3d printer. As i say the dupont conectors crimp fine, so if i can make a housing to mount them, it would solve the problem.
Its really anoying though, one of the reasons i bought the speeduino was i thought it would be so simple to do the plugs on the ecu, on my microsquirt i redid the ampseal conector and it was hard work. wish i had gone microsquirt.
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RumHam
Part of things
Posts: 43
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bmw2101 I have to deal with these little bleeders all day! Have you got a corresponding molex part number for the crimps? It is a bit of a black art and it’s a lot to do with wire strip back length, wire gauge, and the forming in the tool. It’s catch 22 because the genuine tools are ££ for something you might not use much but the cheap tools can be hit and miss in terms of crimping quality. We have got loads of crimps that are the same if not similar, I can run you off a load and post them with a 1m tail length?
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i don't know the molex number, its seems a dark art like you say. I bought some prewired connectors from ali express yesterday, will take ages to come but there is still loads to do to the car. thankyou!!!
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RumHam
Part of things
Posts: 43
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No worries, I’m back in work tomorrow so if you change your mind just give me a shout. I can probably have a guess at the part numbers from your previous photos.
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