28AWG Wire Splice Ideas?

Discussion in 'General Electronics Chat' started by newothegreat, Jun 22, 2017.

  1. newothegreat

    Thread Starter Member

    May 3, 2012
    26
    1
    Hello,
    I just received some custom components that have short wire leads coming off them, and it turns out the leads are about 5mm too short. I need to add a short length of wire onto the end of the leads to extend it. The wire needs to be able to bend in a few different places, so I can't solder it since it would be too brittle, and the solder would wick into too much of the wire, preventing it from bending where I need it.

    My plan was to splice the two wires together using a very narrow crimp band, so that the wire could still bend where I needed it. After a few hours of searching, I could only find one part that seemed like it would work, but the crimper and applicator were all together around $13k, which is too much for this rework job since I'm only going to need it for a couple hundred crimps. This is the part:
    https://www.digikey.com/product-det...y-amp-connectors/63621-2/A111513CT-ND/4142899

    Does anyone have any suggestions?
    -Crimp wire splice
    -2x 28awg wires in a "thru-splice" configuration
    -preferably 2mm wide (in the direction of the wires)
    -inexpensive tooling hopefully

    Thanks,
    Owen
     
    Last edited: Jun 22, 2017
  2. crutschow

    Expert

    Mar 14, 2008
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    13k?
     
  3. newothegreat

    Thread Starter Member

    May 3, 2012
    26
    1
    $13k
     
  4. crutschow

    Expert

    Mar 14, 2008
    19,515
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    Thirteen thousand dollars?
    Is it solid gold?

    How about a terminal like this.
    You could double the 28AWG wire over to fill the 22-26AWG opening.
     
  5. newothegreat

    Thread Starter Member

    May 3, 2012
    26
    1
    That's how they get you. They'll charge you 10 cents for the part, but $10k for tools to make it work.

    That component is the kind of thing I'm looking for, but it's too long for what I need. It's a about 12mm long, and I need it to be 2-3mm maximum.
     
  6. crutschow

    Expert

    Mar 14, 2008
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    Don't know if they make anything that small.
    Could you cut them to the length you need?
     
  7. Papabravo

    Expert

    Feb 24, 2006
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  8. strantor

    AAC Fanatic!

    Oct 3, 2010
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    solder splice but make your wires 2" longer than needed, then loop around and zip tie together so the splice doesn't need to bend.
     
  9. MaxHeadRoom

    Expert

    Jul 18, 2013
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    That sounds like rubbish! I have bought Weidmuller tooling in the past which is considered one of the top of the line in tooling, they are not cheap, but NO where near that.
    Ebay you can get the cheaper versions for a few $$$s.
    Max.
     
  10. dl324

    AAC Fanatic!

    Mar 30, 2015
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    1. Put the solder joint in a place where you won't need it to bend.
    2. Replace the entire wire instead of splicing.
     
  11. newothegreat

    Thread Starter Member

    May 3, 2012
    26
    1
    Thank you for the replies, everybody. Unfortunately I do not have much space to work with, since the lead coming off the wire is only 14mm to begin with. I can't really add in a solder splice where it won't need to bend - almost the entire length of the wire needs to bend! Also, there is no room to add an additional wire loop.

    The wire leads are integral to the components, and are potted in epoxy, so there really no way to replace the wire leads without destroying the component itself.

    $13,000 definitely is a lot of money for a crimp tool, but it's not a completely outrageous amount of money. The only tools that can crimp that particular splice band are high-end automated crimp tools used to high volume production. It's at the high end of the cost spectrum, but not completely unreasonable (after all, some companies are buying them...).

    What I was really after, was to see if anyone had a suggestion for a similar crimp band that could splice together two 28AWG wires, and was as small as possible.

    Thanks again.
     
  12. Alec_t

    AAC Fanatic!

    Sep 17, 2013
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    1mm bore copper/brass tube (from old bulb-type thermostat?) cut to 1.5mm lengths. Solder will be drawn into it by capillary action and remainder of wire would remain bendable.
     
    djsfantasi likes this.
  13. strantor

    AAC Fanatic!

    Oct 3, 2010
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    Yeah, or you could just crimp the tube.
    Cheapo hydraulic crimper should be able to do it no problem.
    https://www.harborfreight.com/hydraulic-wire-crimping-tool-66150.html
    I have this tool and it is one of the better tools HF sells.
     
  14. KeepItSimpleStupid

    Distinguished Member

    Mar 4, 2014
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    FYI: Note the drawing says the part is obsolete.

    Spot Weld?
     
  15. RichardO

    Senior Member

    May 4, 2013
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