Measuring wire size and matching with terminal

[cajocars]

I’ve bought a length of 25mm2 cable and I’ve tried to crimp a connector

My crimper is metric and can be set to 50/35/25/16/10/6 mm2

The connector that came with it are AWG 4/6/8

I first tried the 25mm2 cable in one of the biggest connectors (AWG 4), set the crimper to 25, crimped it and the wire came striaght out of it



Then I saw I could also fit the wire into the AWG6 connector, tried crimping with the same setting on the crimper (25) and it also came out
I then set it to 16 and it crimped, it stays in, but it doesn’t look very nice


This is the crimper

Glarks 42Pcs Battery Cable Lug Crimping Tool Wire Crimper with Cable Cutter and Wire Lugs Ring Terminal Connectors and Heat Shrink Tubing for 10, 8, 6, 4, 2, 1/0 AWG Wire Cable Cutting and Crimping https://amzn.eu/d/90hiSxZ

None of the two connectors I tried crimped correctly with the 25 set on the crimper; now I’m not even sure the cable is 25mm2, how can I be sure?

 

[sunshine_eggo]

See conversion:


I have the same one.

I find that I need to go up one size and crimp twice, 90° apart.

For 4awg, I would crimp w/16 as well. Looks like shit, but it works.

 

[cajocars]

Thanks, also there were some ‘metric’ (as you can see from the picture) connectors
The 25mm2 wire fits perfectly into the 16mm2 connector, why?

Note that the connector reads ‘16’ and the wire ‘25’

 

[sunshine_eggo]

Thick copper with flared end is good.

Those like the above are not as high quality.

 

[cajocars]

Thick copper with flared end is good.

Those like the above are not as high quality.

I heard the same, but why?

 

[sunshine_eggo]

I heard the same, but why?

Thinner, so they don't hold the cable as tightly.

 

[Delphinus]

Thanks, also there were some ‘metric’ (as you can see from the picture) connectors
The 25mm2 wire fits perfectly into the 16mm2 connector, why?

Note that the connector reads ‘16’ and the wire ‘25’

There are some that accept 2 sizes but your case is poor quality of terminals and crimping tool, unfortunately those days amazon is full of chinese crap. Your crimping tool was not cheap buy good 25m2 terminals and if you cannot crimp with the tool set for 25, return it and ask a refund.

From left to right 16 - 25 - 35 - 35 - 50 mm2 all are copper the drill bit is 2mm for reference the 16 and second 35 are not certified but good quality, if you are in Europe buy terminals with CE logo



Those crimping tools apply force over a small area, crimp at least 2 or 3 times in sequence to increase the area, like I did in the photo, those were my first and they are not correct, now I crimp twice 90° apart like sunshine recommend.

 

[radomvam]

Totally get the struggle with the Amazon maze – seems like a game of "Find the Quality Needle in the Chinese Haystack." Your advice on investing in decent tools and certified terminals is pure gold. Bummer about the uncertified ones, but at least you're rocking that CE logo pride in Europe! And hey, for those who need a visual size check, hit up ruler.onl and measure your way to crimping success!