TECHNICALLY SPEAKING
was incorrect wire size for the size of plug
being used. Hearing that PowerBox Systems
was producing plugs and sockets to match
their excellent heat resistant premium servo
wire it was time to have another go to wire up
my latest model, a Rotkoski Sabre (BVM plus
22%, a perfect size for ease of access and
handling), and this time, complete success.
Making the plugs and sockets proved very
quick and straightforward but I did discover a
few simple techniques to make easy work.
Firstly, the tools - of course, one needs a
crimper suitable for the diameters of wire we
are using, mine suits 28, (our size) 24 and 20
awg wire.
Secondly a small wire stripper of the type
which automatically adjusts to the wire being
stripped; both of these tools can be purcha-
sed from any electronics store for a modest
sum. Finally a pair of small pointed nose pliers
is required to nip the flanges on the pins.
The procedure now is very simple:
About 5 mm of insulation is stripped from the
cable and the wire is twisted to enable easy
insertion into the pin.
With the cable pushed into the pin far enough
for the two flanges on the pin to grip the insu-
lation the flanges are gently nipped with the
pointed nose pliers to hold the cable and pin
together.
The pin is now placed, inverted, flanges down
into the “V” of the crimper and the crimper fir-
mly closed, the pin is now securely attached
to the cable. The pin is now inserted into the
plastic plug so that the “latches” in the plug
engage the recess in the pin. When all three
strands of the cable are inserted into the plug
it’s almost job done.
I like to grip the three strands of the cable with
heat shrink tubing adjacent to the plug but I
found that when shrinking the tubing it was
easy to cause distortion of the plug, they are
quite sensitive to high heat. I also found it best
to insert the plug into a socket whilst shrinkingA wire stripper greatly facilitates preparation of the cable for insertion into the pins.The crimper is required for final assembly of wire to pin.Old but good, a pair of small pointed nose pliers is perfect for nipping the
flanges on the pin to hold the cable ready for insertion into the crimper.The pins are inserted into the crimper
face down, a firm squeeze and job done!Gladwin_Layout 1 07/03/18 11.58 Pagina 5