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Mark and Lisa make a good point, that a proper crimp
is easier to accomplish than a proper solder joint. By proper crimp I
am talking about a four lobe crimp on a tubular wire receiver using a
M22520 ratcheting crimper ($200 - $500) NOT a "B" crimp on a stamped
contact using a $20 pliers type crimper. If you must use a connector,
using MIL spec pins and crimper are the safest options. If you need to
make a connection that will remain connected for most of the life of
the airframe then solder and heat shrink will yield the lightest,
cheapest, and reliable connection.
The ability to suspend a 5 Lb. weight, while entertaining, has little
relevance in the evaluation of the suitability of a connector system.
Static loads don't fail connectors. Corrosion, thermal cycling and
vibration (with its friends fatigue and fretting) are the long term
culprits. The very design of the Fast-On invites moisture to come and
stay a while.
If Fast-Ons were such a great value, wouldn't you see them in late
model cars or avionics?
Having stirred the connector pot, how about this:
The only wire you should use (except coax or proprietary cables) is MIL
22759 (single wire) or MIL 27500 (shielded) and you should only use
thermal strippers (hot blade) to strip the insulation. Never use PVC
insulated wires, including wire that may be included as part of some
products, and never use sharp edge strippers. PVC has a lower melting
point than Tefzel (used in the MIL wire) and sharp edge strippers often
nick the wire's conductor strands. These nicks form stress
concentrations that, with vibration and the copper's work hardening,
lead to mechanical failure of the conductor.
Reliability is a product , in part, of attention to detail.
Regards
Brent Regan
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