How to crimp Dupont Terminals, and why you SHOULDNT 

Straight to the point and well laid out. Thank you klsir!

“Take a look at these wires that you should’ve used instead.” 🤣 Alright, broseph. You’re right; I’m just gonna go with the pre-assembled ones from now on. Thanks!

If the wings aren't crimped properly, just crimp them again in a smaller cavity. I usually crimp them twice by default and it works like a charm every time. Much easier then trying to fix them with regular pliers.

Hanging the wings off the shelf is the hot tip here. I'm a molex baby so I had no idea what to do without a locator. I still think the locator is worth every penny though

I find it easier to hold the pin lightly in the jaws (usually one click) and then pull it through until it limits on the shelf. This saves you dropping the pin. To strip the right length of insulation I have mounted a spare pin on a piece of wood and use that to to check the length of the stripped wire. I use silicon insulated 24 AWG wire, you can strip this with your finger nails, no chance of nicking any of the strands of wire! My crimpers don't crimp the insulation properly either, a right PITA.

i like your style mate.

Evidently this crimper does /not/ have proper dies for DuPont and Mini-PV connectors, as the female die on it is designed to fold the tabs back on to the wire, whereas the DuPont design uses a circular shape instead. Thus, why your crimped terminal didn't fit in to the housing. Also, while I'm struggling atm to find documentation of this, it seems the SN-28B is also not appropriate for JST connectors, as those need a 4mm deep die, whereas the 28B's dies are 7mm deep - so you can't even use them for a single-operation crimp without crushing either the connector-side or the insulation-side. I'm feeling really frustrated that this stuff is evidently so difficult to get right. It really doesn't make sense to me. Even if these aftermarket crimps are cloning the OEM tooling, what prevents them from actually copying the geometry exactly?? How are they fucking up these critical details? Really sucks that it seems you actually have to pay hundreds to get proper tooling that works.

Currently shopping for crimpers. Looks like SN-025 is the model to use for dupont terminals, it gives the correct round crimp on the insulation clamp and B crimp on the conductor.

Good info.

The trouble with those pre-made cables is that they have individual single pin connectors, which you advise against. So do you recommend buying them, removing the single shells and replacing them with the appropriate shell for the number of ways you actually need?

Good point, took me two hours to make an 8 pin harness. 😢

28 AWG? I use 22 AWG stranded wire and it works fine. It seems evident that smaller sizes will also fit.

I just came here to look at the fingers in the thumbnail.