Dumb question.

[MrAubin]

Is it ok to fill the gap with more wire ? A cleaner job than this. This was to see if it could be pulled apart with 2 pairs of pliers. It's solid but otherwise it's presses out the sides and looks like @ss. If I can't fill the space with more wire I'll order Ancor terminals that will wit but they won't be closed end lugs. Opinions accepted. Running less than 12 amps through these. If that matters. Thanks.

 

[jimbob420]

I have folded over wire loads of times when I haven't had the right size lug or crimp - it's fine. You can obviously cut off the excess protruding wire if you end up with any and tape or heatshrink over the exposed copper.

 

[kenryan]

Yes, you can add wire, and you don't need to go to extremes (pulling with pliers) when testing pull strength. Yes, test them by pulling but you are not going to be using these cables for hoisting! Pulling with pliers is unnecessary and could be counterproductive. More important is that when you install the cables, you provide adequate stress relief so that there is never any force on the connections. Also important (and what you are addressing by adding wire strands) is that the crimp is gas tight. A better solution would be to get the correct terminals for the wire size being used.

 

[Supervstech]

Wear rubber gloves when folding the long strands.
Hand oils compromise the surface of the wire weakening the joint.

 

[MrAubin]

Yes, you can add wire, and you don't need to go to extremes (pulling with pliers) when testing pull strength. Yes, test them by pulling but you are not going to be using these cables for hoisting! Pulling with pliers is unnecessary and could be counterproductive. More important is that when you install the cables, you provide adequate stress relief so that there is never any force on the connections. Also important (and what you are addressing by adding wire strands) is that the crimp is gas tight. A better solution would be to get the correct terminals for the wire size being used.

I only pull on the test piece I wouldn't risk damaging the internal windings of finished product. Once I'm happy with the method I simply repeat it.

 

[MrAubin]

Found crimping 12 times rotating each time only crimping a little more each rotation gave me this end result and again she's pliers pull proof. Oh ya, aaand I had to use a smaller awg size to crimp it.last pic shows wire awg and ring terminals being used.

 

[time2roll]

Is it ok to fill the gap with more wire ?

Considering the wire size I would far prefer to get the right lug. Yes in a pinch I would fill with wire and move forward.
I usually keep the insulation closer to the lug. Is it better to have that gap?

 

[MrAubin]

No I would never terminate anything like that or I'd fire myself from using tools. I did that one so it was easy to show what I meant by filling the gap. And other crimps were all test crimps here's finished crimped but not heat shrunk yet, it's enroute to my house still. Like I said around 8 rotations during crimping with 12 awg dies kept all the material tight in the press allowing me to use the "12/10awg" wire lugs on my 10 awg Ancor marine wire. Thanks everyone for your time and input. This site is amazing.