Building automotive relays…

[Razorhunter]

Can someone please clarify what terminal crimpers I need to build automotive relays as I have pictured?
From what I can gather from the insanely overcomplicated subject of crimping, these are uninsulated “quick disconnect” terminals that can also be referred to as FASTON? terminals?
I’m sure you guys will be right along to inform me of at least another thousand or so names for these things.
Bottom line is I need to know what terminal crimpers I need to build the relay pictured and please let me know if it matters whether my relay is using .250” terminals or the smaller .110” terminals?
Do they require a totally different set of crimping dies?
If anyone knows of the mother of all webpages explaining various crimp and terminal types I would be overjoyed to hear about it. To date, I’ve shockingly never found anything close. It’s always tidbits of crimping info here and there, with no mention of all the various terminology used for the exact same terminals etc etc.
I would think someone would’ve covered this ten times over by now. Maybe I’ve just missed it and it is out there?

 

[wssix99]

At the bottom of the website page you are showing, they have the spare terminals that detail they are Metri-Pack 630 Series terminals. You need a special crimper with a die specifically for the Metri-Pack 630 terminal AND wire gauge size. (The crimps will be different.)

This GM booklet has the OEM part numbers for the terminals: https://www.weber.edu/wsuimages/automotive/j-38125-620b terminal repair booklet.pdf

^ You can use the booklet and tables to sort through all the terminals and find your part numbers. The tables will also give part numbers for the Delphi crimpers. You can often get good deals on these through eBay or you can find generic versions also.

 

[cgrutt]

I have an old MAC TCT1028 open barrel style crimper that I'd probably try on those terminals but there is probably a specialty crimper that they want you to use for those.



Look at catalog on attached link some good info on terminals and crimpers in general at beginning of document.

https://www.te.com/content/dam/te-com/documents/application-tooling/global/1-1773865-2_Commercial%20Manual%20Hand%20Tools_WEB.pdf

 

[The Metric System]

There are many different types of crimp systems, far too many to make a comprehensive list.

Even the same type of terminal (like your 0.25" Fastons) can require a different type of crimper on the wire end depending on things like whether it's single or double crimp, straight vs flag, or the intended wire gauge.

Often the crimpers are manufacturer-specific, so otherwise interchangeable 0.25" Fastons made by Molex might specify a different crimp tool than ones made by AMP.

These crimp tools are expensive and generally only suitable for use on one particular type of crimp. They are worth every penny in an industrial application where you are making thousands of crimps a day without much time to inspect each one and where rework is a big process issue.

IMO they are overkill for a home/hobbyist application, and with a bit of practice and care you can get good crimps with this style of inexpensive ratcheting interchangeable-jaw crimpers.

https://www.amazon.com/dp/B0B56J8912/?tag=atomicindus08-20

 

[mm08822]

That has been a standard crimp style for years.
I suggest you buy similar cheap ones and practice with whatever crimp tool you anticipate using with scraps of the same wire gauge. Teach yourself how to crimp this style. Not always a single step.

Also note how the terminal is retained. There is usually some whisker that deflects while pushed in and rebounds within the shell to keep it retained. Good to know before assembling. Sometimes a jeweler's screwdriver can accomplish the release.
Edit: This series uses a terminal positioning insert which accomplishes the same.

On another point,
what is the amperage of the load you are switching?
Rating of the relay contacts?
Wire size?

 

[Razorhunter]

So far I’m hearing Fastons and Metri Pak 630’s yet never once have I seen a “metri pack 630” or “FASTON” advertised crimp tool.
I guess I just thought there’d at least be some standard terminology more commonly used for these crimps/terminals which have been used forever in numerous industries.
Be that as it may, I’m replacing a couple FASS fuel pump relays. They are 40a relays on 10awg wire. They are overkill and the pumps only pull less than 10a, but that’s what the mfr sends so that’s what I’ll go back with.

 

[cgrutt]

So far I’m hearing Fastons and Metri Pak 630’s yet never once have I seen a “metri pack 630” or “FASTON” advertised crimp tool.
I guess I just thought there’d at least be some standard terminology more commonly used for these crimps/terminals which have been used forever in numerous industries.
Be that as it may, I’m replacing a couple FASS fuel pump relays. They are 40a relays on 10awg wire. They are overkill and the pumps only pull less than 10a, but that’s what the mfr sends so that’s what I’ll go back with.

This looks similar to the MAC I posted above but they do mention FASTON Type-B in description. I'm sure there are others that do so as well.

FDT10040 - Crimping Tool for Open Barrel Connectors (Faston B-Type Crimping) - 22-10 AWG

Crimping Tool for Open Barrel Connectors (Faston B-Type Crimping) Features: Crimping Range: 22-10 AWG Slot 1: 18-16 AWG Slot 2: 14 AWG Slot 3: 12-10 AWG Slot 4: 22 AWG Hardened steel frame Burnished finish Ergonomically designed comfort grip handles Cross References Cross Reference Parts:None...

www.ferrulesdirect.com

 

[cgrutt]

More info

https://www.farnell.com/datasheets/1658358.pdf

 

[The Metric System]

So far I’m hearing Fastons and Metri Pak 630’s yet never once have I seen any crimper advertised with either of those terms.

"Faston" is a trademark of TE Connectivity for this type of quick-insert tab. Not all quick-insert tabs are technically "Fastons" although the term is used in a generic way similar to Xerox.

The term refers only to the quick-insert tab on the free end of the terminal, it does not have any bearing on the direct wire connection side.

This style of terminal can be made with dizzying array of wire connection designs, including a wide variety of crimps, solder lugs, or even screw/rivet holes.

Their ubiquity in industry drives a lot of variation. For example, Digikey currently lists more than 5,000 versions of the concept available for purchase.

FASTON terminal - Wikipedia

en.wikipedia.org

 

[mm08822]

There are several crimpers that come up searching for crimpers for this series that do mention 630 in their description. However, they are all ~$120ish.

 

[whateg01]

There are many different types of crimp systems, far too many to make a comprehensive list.

^^^this

...
I guess I just thought there’d at least be some standard terminology more commonly used for these crimps/terminals which have been used forever in numerous industries.

But often, a hobbiest can get by with something similar as has been indicated in others' comments.

 

[wssix99]

Each terminal manufacturer has a proprietary design and crimp.

We can make this easier - what cars do you own?

 

[The Metric System]

It's a bit of an expensive option, but you can also buy pre-crimped pigtails and then just land on the bare wire however you prefer.

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

 

[Razorhunter]

Each terminal manufacturer has a proprietary design and crimp.

We can make this easier - what cars do you own?

I’m usually working with aftermarket truck parts totally unrelated to any specific auto mfr. I get your point however.

 

[Razorhunter]

It's a bit of an expensive option, but you can also buy pre-crimped pigtails and then just land on the bare wire however you prefer.

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

Sure. I’ve done this for years with heat shrink splices and there is a time and a place for that for sure. Other times I prefer to avoid the splice and just build the harness or component out the proper way so to speak.

 

[BillK]

Depending on how much you plan on doing they make tools with interchangeable die sets that will do almost anything:

Crimping Tool Set 8 PCS with Interchangeable Dies and Wire Stripping T

This versatile crimping tool set works with heat shrink, insulated nylon, non-insulated, open barrel, ferrule, and flag terminals. Its precise ratcheting mechanism was calibrated to make proper uniform crimps every time. This crimper tool set includes precision wire stripping tool.

wirefyshop.com

I have been working with electronics my entire life both as a profession and as a hobby. I probably have 6 or 7 different crimp tools I have accumulated over the years to cover all of the bases.

I will say that the usual "you get what you pay for" definitely applies here.

 

[joe_padavano]

The terminals in the OP's initial post are Packard 56 style terminals. Use a correct Packard 56 crimping tool. I have a set of MSD jaws in a generic crimper tool frame that do a great job on these, including crimping both the conductor and insulator at the same time. The result looks just like the OEM crimps. These are NOT MetriPack or anything else, they are Packard 56.

 

[whateg01]

The terminals in the OP's initial post are Packard 56 style terminals. Use a correct Packard 56 crimping tool. I have a set of MSD jaws in a generic crimper tool frame that do a great job on these, including crimping both the conductor and insulator at the same time. The result looks just like the OEM crimps. These are NOT MetriPack or anything else, they are Packard 56.

So the correct tool is a generic tool?

 

[Razorhunter]

The terminals in the OP's initial post are Packard 56 style terminals. Use a correct Packard 56 crimping tool. I have a set of MSD jaws in a generic crimper tool frame that do a great job on these, including crimping both the conductor and insulator at the same time. The result looks just like the OEM crimps. These are NOT MetriPack or anything else, they are Packard 56.

Thank you Sir.

 

[Razorhunter]

Depending on how much you plan on doing they make tools with interchangeable die sets that will do almost anything:

Crimping Tool Set 8 PCS with Interchangeable Dies and Wire Stripping T

This versatile crimping tool set works with heat shrink, insulated nylon, non-insulated, open barrel, ferrule, and flag terminals. Its precise ratcheting mechanism was calibrated to make proper uniform crimps every time. This crimper tool set includes precision wire stripping tool.

wirefyshop.com

I have been working with electronics my entire life both as a profession and as a hobby. I probably have 6 or 7 different crimp tools I have accumulated over the years to cover all of the bases.

I will say that the usual "you get what you pay for" definitely applies here.

Yes Sir I too have many ratcheting style crimpers that are very costly as well. Interchangeable jaws, etc.
As long as I know what to buy, I’m always willing to buy the proper tool or jaw insert when necessary. My problem usually lies in identification/terminology.

 

[The Metric System]

So the correct tool is a generic tool?

He's saying that the correct tool is a generic crimper that has replaceable jaws, with the jaws selected to be correct for the specific crimp being made.

 

[Neohio]

I have these following crimp dies for those connectors.
What city/state are you in?
I can crimp some on some wire and send them to you.

624 1510 3 012 RT - Rennsteig | TOOL-CDIE50 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, 1.0-3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

624 1511 3 012 RT - Rennsteig | TOOL-CDIE56 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, .5, .8, 2x3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

624 1509 3 012 RT - Rennsteig | TOOL-CDIE57 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, 2x.5/.8, 2x2.0, 2x3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

 

[Razorhunter]

I have these following crimp dies for those connectors.
What city/state are you in?
I can crimp some on some wire and send them to you.

624 1510 3 012 RT - Rennsteig | TOOL-CDIE50 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, 1.0-3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

624 1511 3 012 RT - Rennsteig | TOOL-CDIE56 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, .5, .8, 2x3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

624 1509 3 012 RT - Rennsteig | TOOL-CDIE57 - Corsa Technic | Rennsteig PEW 12 Die Set for Delphi/Aptiv MP-630 Unsealed terminals, 2x.5/.8, 2x2.0, 2x3.0 mm2

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

Thank you so much for the offer but I’ve got to cut an old corroded relay socket off and crimp a new one back on. In other words, directly to the harness and avoiding any splices. I appreciate your kind offer though.

 

[joe_padavano]

So the correct tool is a generic tool?

How did you get that from what I wrote. One more time, MSD sells different jaws (dies) for different terminals. One of them is P/N 3509, which will make the correct crimp on Packard 56 terminals as well as on WeatherPack terminals. These dies fit into most generic ratchet crimp frames that are set up for replaceable dies. I got a generic frame at a swap meet for $15 and the MSD dies fit fine. You can also pay stupid money for an official Kent Moore Packard 56 crimp tool. Personally, I'm cheap. The Kent Moore tool in the last photo is currently $285 on ebay. Too rich for my blood.