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Revan654

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I'm having problems doing the double wire crimping when creating my PSU cables. I have tried 16 & 18 AWG. Both seem to thick to fit in a Female ATX terminal. Is their any tips crimping the wire to create a double wire?

I have a EVGA 1600W T2 PSU, Pin layout shows a few double wires.
 
With a good crimper and a steady hand you can probably make a decent fist of double crimping 18awg wires - but you will be very lucky to get as good a result as your stock cables, which have been built with industry standard tools and without the hindrance of sleeved wiring.

As for 16awg you would probably have to reduce each wire to half its thickness and bind them together with the crimp.

It may be worth looking at the gauges of the doubled wires in the standard cable to see if one of them is one or two gauges thinner than the other. If that is the case your best bet is to buy some thinner wire to preserve the gauge difference and then both crimp and sleeve them together.

But your real problem with double crimping wires at the motherboard connector is the virtual impossibility of having two sleeved wires emerging cleanly from one connector point - and then merging smoothly with the rest of the cable where it loops off the motherboard.

There is a way of fixing sleeve at a midpoint in the wire which would involve destroying a couple of Mini-Fit terminals, and this could help to solve the problem of getting two sleeved wires into one connector point, however, that still leaves the problem of neatly bundling more than 24 wires from a 24 pin connector.



In the end the best decision is to split the wires as close to the motherboard as you can get. If you are happy with using a soldering iron
will show you how to do that.

If not you could try a heatshrinkless knotted joint as follows - there's no need to use Polymorph, you could use hot glue or even a general purpose glue instead as long as it re-insulates the wires and keeps hold of the messenger wire sleeve.




The two key points are to preserve whatever gauge difference you find in the stock cable and keep the joint as close to the motherboard as you can.

 
Do NOT follow Lutro's video for soldering two wires together! I cringe every time someone recommends that video. Lutro has forgotten more about sleeving wires than any of us will ever know but the man does NOT know the proper way to make a soldered splice (he even admits it himself). Solder should never be all that holds wires together; all the solder should be doing is ensuring a good electrical bond.. Enough insulation should be stripped from the wires to allow them to be twisted together. When twisted properly, it should be pretty much impossible to pull them apart. I did a quick splice job a while back to show what I mean (excuse the lousy photos; it was late, well past my bedtime). I also used #14 wire because it was handy and easier to photograph.

Here I have stripped the wires and untwisted the strands like Lutro did.



Here, they have been twisted together. I would have to work hard to pull them apart at this point.



And here is the splice after soldering (I was too lazy to dig out my soldering iron and wait for it to heat up so I just used my soldering gun).



I didn't heat the wire long enough to burn off all the flux because I was melting the insulation (I was also using too large diameter solder; I just grabbed what was handy). One should use only enough solder to ensure every strand has been coated but not so much the solder is piled on; you should still be able to see the strands. The exposed conductor will be pretty much level with the insulation on the single wire coming off the splice once you put a heat shrink sleeve on it. Once you actually sleeve over the wire and the heat shrink sleeve over the exposed conductor, the joint there will barely show, if at all.

Again, solder should only ensure electrical conductivity. For the same reason, I do not recommend solderless joints and splices other than crimped connections.
 
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Wow! This is wrong in so many ways....



Lately I've been trying to slide the strands together before twisting. This shows just two wires, but you get the idea.

 
I never had much luck trying to slide the strands together before twisting. They would pull apart too easily.
 
Quote:
Originally Posted by billbartuska View Post

Wow! This is wrong in so many ways....

Lately I've been trying to slide the strands together before twisting. This shows just two wires, but you get the idea.

interesting, I wonder if you used thread to lasso both ends just to keep it bundled long enough to get the solder to flow creating a real tight splice without any ends protruding?
 
Quote:
Originally Posted by BinaryBummer View Post

Quote:
Originally Posted by billbartuska View Post

Wow! This is wrong in so many ways....

Lately I've been trying to slide the strands together before twisting. This shows just two wires, but you get the idea.

interesting, I wonder if you used thread to lasso both ends just to keep it bundled long enough to get the solder to flow creating a real tight splice without any ends protruding?
You haven't been paying attention. You must have a secure mechanical connection before soldering. All the solder is supposed to do is ensure a good electrical connection, not hold the splice together. If you can pull the splice apart before soldering, the splice can fail after soldering.

Laying the wires side by side, then twisting them may not look pretty but, if twisted tightly enough, they will not pull apart. The rougher appearance will be covered with the heat shrink sleeve you put over the joint to insulate it and the sleeving over that. If done correctly, the joint won't even show after sleeving.
 
Quote:
Originally Posted by Revan654 View Post

Quote:
Originally Posted by msd0 View Post

If your using the pin in your picture, it's the wrong one. You need to use a mini-fit jr pin like this:
If I was creating ATX cable sure, but like I said It Molex power pin.
In your first post, you referred to an ATX pin.
 
Quote:
Originally Posted by Revan654 View Post

Quote:
Originally Posted by Lady Fitzgerald View Post

In your first post, you referred to an ATX pin.
I'm creating more then one cable that has double wires.
How were we supposed to know that?
 
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