How to Crimp Wires Without Crimper?(Easy Guide)

The unique thing about any circuital connection is its ability to create a closed-loop. Howsoever complicated be the connections, you would find them getting terminated at some point. And when it comes to closing the connections, crimping comes as a popular tool.

Crimping involves using crimp connectors to terminate the stranded wires and maintain an air-tight connection within the setup. Applicable in wires of multiple cross-sections, you would not find any major tooling or process investment. The only thing that needs to be taken care of is that there must not be any sharp edges.

With all of these benefits, you might be thinking of the next level- what if you can crimp the wires without using any crimper? Will this process be a better alternative to other wire connections? Do not worry, we have got it covered for you through our discussion for the day- how to crimp wires without crimper?

Is Crimper the Only Tool to Crimp Wires?

Crimper is a standard tool for crimping the wires and establishing a firm connection. That being said, it is not the ultimate equipment for the process. In events when you would not find the standard tool readily, you can go for either of the alternatives mentioned below:

  • Swiss knife and flat head screw, which is considered to be quite a cheaper alternative when compared to the standard tool. The main job of the knife and screwdriver is to just orient the wire within the slot, and press the metal contact.
  • Hammer and chisel, which should be your last option for crimping wires together. You need a good amount of self-control to use the set, and ensure that no damage is brought either to the wire or slot during the process. 
  • Pliers, which can be an excellent alternative for holding the wire tightly. It would not be calibrated as the standard tool, but with practice, you would have gained a fair idea of the dos’ and don’ts of the process. So, you can use the same for twisting. 

Go for these alternatives only when you do not have the standard tool or are under an emergency. Good knowledge and precision is needed for these alternatives to render a finish like crimpers. 

2 Methods of Crimping Wires Without Crimper

Method 1 Of 2: Using Swiss Knife and A Flat Head Screw Driver

One of the popular alternatives of crimping tools is a swiss knife and flat head screwdriver combo. For those looking for answers on how to crimp RJ45 without a crimping tool, this is the duo for you. 

The versatility of the swiss knife combined with the ease of operation of screwdrivers makes it a popular alternative.  

Items and Tools You’ll Need

  • Swiss Army knife- 1 (Must have a blade, can, and bottle opener features).
  • Flathead screwdriver- 1
  • RJ45 connector
  • Network cable

Please go through the given steps to successfully crimp an RJ45 connector with this given set:

  • Take 2-3 cm of the cable and cut out its insulation with the cutting blade of the knife. Be very sure that you are not cutting the internal wires during the process.
  • Identify the color sequence of the wires as per the regulatory norms of your location. Refer to journals and materials to know more about it.
  • Now it is time to cut the extra length of the strings and make crimping an easy job. Take the cutter and leave only 1.5 cm of the internal wires. Place the cable on a hardboard while conducting the activity.
  • Place the cable inside the transparent connector and ensure that the color codes are met within the slots. Again, refer to your regional codes and standards. You can use the screwdriver to help in proper orientation within the slots. 
  • Now comes the step for crimping. Use the can opener tool to make a bypass for each string, and set them in a given line.
  • Fix the connector with the cable firmly.

And then hola! You are ready with RJ45 that has been made out of the non-standard tool.

Safety Tips and Precautions

  • Be sure not to cut the internal wires while removing the insulation. 
  • Use hard surfaces for cutting the wires. 
  • Be precise while cutting the cable. 

Method 2 Of 2: Using Hammer and Chisel

For those of you who are looking for answers for how to crimp a ferrule without a crimping tool, you have hit the right spot. Hammer and chisel work as the best alternative in this situation. 

Because of the efforts put up by the hammer, the strength of the crimp is commendable and matches that of the standard tool.  

Items and Tools You’ll Need

  • Cable- 1
  • Ferrule- As per your requirement
  • Hammer- 1
  • Chisel-1 

Follow the steps given below to complete the activity:

  • Pick up an aluminum sleeve as per the size of your cable.
  • Use the cable to make a loop through the ferrule and pass it outside of the same.
  • Adjust the loop based on your sizing requirements. 
  • Once the cable has entered within the sleeve, use a chisel and hammer combo to orient the same and make dents.
  • Dents on the sleeve would ensure the proper strength of the cable. 

Safety Tips and Precautions

  • Be careful while applying the force to strike the hammer. You do not want to break the sleeve or crimp.
  • Use gloves while doing the activity, as there may be chances of small cuts and burrs. 

In addition to this section, you would also get the answer to how to crimp wires with pliers. You can use this on wires of small diameters. 

Items and Tools You’ll need

  • Required cable
  • Aluminum sleeve
  • Plier

The following steps would help you in executing the process:

  • Make a loop between sleeve and ferrule, just like the previous ways.
  • Place the sleeve within the plier’s jaw, and smash it to make a dent.
  • Repeat the process for multiple dents across different corners.
  • Press the plier until the fitting close the cable.

Here, you need to take care of not smashing with an excessive force that may damage the wires. Also, do not forget to visit our latest article- Can you use CPU thermal paste on GPU?

Would These Methods Be as Good as Crimping with Crimper?

Please do note over here that you would find a difference in strength when compared to the finish given by a crimper. Yes, it depends upon the type of alternative that you are planning instead of the crimper.

For example, under hammer and chisel, the strength would be even greater than that of the crimper. It is because you are using force to close the loops and create dents. But extra care needs to be maintained that the internals does not get damaged.

When it comes to a swiss knife, the strength would be lesser than crimper. It is more about precision and accuracy. Similar is the case with pliers also. 

Thus, the moral of the story is that you can proceed ahead even without a wire crimping tool. Weigh down your parameters accordingly, and select the model that best fits your strength and usage requirements. 

How Long Does Crimped Wire Last?

When it comes to benchmarking between different wire joining mechanisms, you would find crimping to be highly effective, and better lasting. It is because of the following reasons:

  • Because of crimping, the connections are well protected from dust, dirt, debris, and other environmental factors. 
  • An air-tight seal is ensured between the cable and the connector, which is often not the case with soldering or other techniques.
  • In the case of soldering, filler material is used which degrades with time. However, that is not the case with crimping, and strength is retained over a period. 
  • Crimping does not require extra skill and can be handled even with unskilled labor. And with this also, you can achieve good strength. 

Such is the number that you can also crimp flag terminals without crimper. 

FAQs

 How to crimp wires with pliers?

The majority of the steps under this are similar to the ones while using a hammer and chisel. Firstly, create the loop within the sleeve, and then smash to make multiple dents around the connector. Finally, press with the plier unless it is firmly established. 

How to crimp flag terminals without crimper?

When it comes to crimping flag terminals without a crimper, you can go for pliers. They help in effective twisting and ensuring a better connection with the connector. Alternatively, you can also go for a swiss knife and use its different cutting tools for achieving the purpose. 

How to crimp a ferrule without a crimping tool?

The best alternative to crimping tools when it comes to ferrule is hammer and chisel. The force exerted by it is highly beneficial for maintaining the required bond between cable and connector. 

How to crimp RJ45 without a crimping tool?

The best alternative for this is a swiss knife and flathead screwdriver. They help in setting the orientation within the connector, and ensure that the required combination is met as per the codes and standards.

How to crimp 4-gauge wire without a crimping tool?

Answer: In this case, you can go for pliers, as such wires are delicate and may not be able to endure the strength of other alternatives like a hammer, chisel, or even a swiss knife. 

How to crimp Deutsch connectors without a tool?

You can follow similar steps while using a swiss knife for crimping, where the cable can be stripped by some millimeters, and then connected with the help of a screw driver or plier.  

Final Words

The final verdict states that you can readily utilize other alternatives in absence of a standard crimping tool. With comparable strength and equally good finish, you can utilize such home remedies for your emergencies. 

Based on your applications, select the alternative that goes perfect for you. Keep referring to the online journals for any help, and do not hesitate to even reach out to us. Keep referring to our website for more of such informative content, like How to clean brushed aluminum laptop? How to clean tempered glass PC? And many more. 

Till then, happy reading and stay safe!