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October 2015 Issue

Joining Two Small Wires

Wires too small for regular PIDG crimp-on connectors can be soldered, but here is a nice alternative that does not involve heat, smoke, or burned fingers. You can use pins from a D-sub connector and heat shrink tubing to create a solid, gas-tight connection. This method is fast, easy, and can be disassembled if needed. This will work on wire up to 20 gauge.

1. Strip and crimp pins as you normally would. Be sure to use the correct crimper for D-sub pins. This is a 4-position crimper that automatically sets the correct depth for the crimp.

2. Slip about 3 inches of 3/32-inch heat shrink onto the wire and connect the pins.

3. Center the heat shrink so you have equal tube over each side of the pins.

4. Verify the pins are fully inserted and shrink the tube. It is important to verify that the pins are fully inserted.

5. Review the shrink to be sure it is fully connected.

D-sub pins and heat shrink tubing.

Be sure the tubing is tight around pins, and the pins are fully inserted.

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