Crimping Terminals onto Large Wire

[George]

What is the ID before crimping?My uncrimped lug inside diameters measure as follows.

The inside diameter of my lugs measure: (within +/-.003 on a sample of 3 lugs each)
SC25 lugs are ø.281”
#4 lugs are ø.282"
SC16 lugs are ø.253"
#6 lugs are ø.236"
I found an IEC standard spec'ing of 7.2mm and 6.4mm (.283" and .252") which is pretty close to my measurements.
A DIN standard spec'ing 7.0mm and 5.5mm (.276" and .216) Way off.
I also found an AWG chart that agrees with your sizes but it was to no stated standard.
In any case I wouldn't think barrell size would matter a great deal since a crimper would squeeze them down to whatever size the dies are with enough force applied. BTW - there's no daylight showing between the dies when closed on a crimp.
When you have a minute would you be willing to measure the two hex dies (4&6) in your crimper across flats? I can't believe both of my crimpers would be off though. Thanks

 

[Jwtsg]

The inside diameter of my lugs measure: (within +/-.003 on a sample of 3 lugs each)
SC25 lugs are ø.281”
#4 lugs are ø.282"
SC16 lugs are ø.253"
#6 lugs are ø.236"
I found an IEC standard spec'ing of 7.2mm and 6.4mm (.283" and .252") which is pretty close to my measurements.
A DIN standard spec'ing 7.0mm and 5.5mm (.276" and .216) Way off.
I also found an AWG chart that agrees with your sizes but it was to no stated standard.
In any case I wouldn't think barrell size would matter a great deal since a crimper would squeeze them down to whatever size the dies are with enough force applied. BTW - there's no daylight showing between the dies when closed on a crimp.
When you have a minute would you be willing to measure the two hex dies (4&6) in your crimper across flats? I can't believe both of my crimpers would be off though. Thanks

🍿

 

[George]

And the winner is... hammer crimper. For $12 this is the way to go. It would be inconvenient for field use but it makes superb crimps. I crimped this one twice but once would have been enough. After one crimp I could not pull the lug off with my bare hands.
I sent a help request to Selterm (the Amazon seller for my lugs) and will post their response if I get one.
Thank you all for your comments and help.