Originally Posted by Lady Fitzgerald
The tool the OP is using has been modified by the vendor to handle #16 wire. The pins come from the same vendor and are designed to handle the wire. Also, he is using wire from the same vendor which has considerably thinner insulation (I have the same wire and it's amazing how much thinner it is). In this video
, the vendor explains all this and demonstrates doing the crimps with the #16 wire.
I have crimped up to two #14 wires to a four pin female Molex power pin but I used a different crimper and pins that had longer wings (those are a wee bit hard to find). The crimper was an el cheapo that crimped the wire and the insulation wings separately. 'Twas a bit fiddly to do, however, especially since I was doing it while the cable was still inside the computer (I needed to add a second four pin power connector to the end of a cable in a rather cramped case and it would have taken hours to R&R the cable instead of the 30 minutes it took to do the job in place).
Warning: Spoiler! (Click to show)
I'm not saying that it cannot be done, you will just not have the same quality with using oversized wires in a terminal that is not designed to handle it. The CMA of the wire must meet the CMA range of the terminal in order to make a quality gas tight connection. This is not to say that failure to follow this will preclude a usable crimp, as it will indeed still function. It will just not be as reliable as a crimp using the appropriate tooling and materials. You say the terminal will accept up to 16AWG wire, so if this true there should be no sizing issues. Looking at the Molex part for this application (assuming we are talking about the same terminal here), they are designed for 14-20AWG wire, which tells me that this is not a gauge mismatch issue.
I have still not seen the photos from the OP, so it is hard to tell what is going on here without seeing first hand. It could just be as simple as improper strip length, or misalignment in the tool. Additionally, if he is crimping wire insulation in the conductor crimp, it will cause the failure that the OP is seeing.Edited by Mattb2e - 10/25/15 at 11:55am