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I prefer the Molex 19001/19002 series of fully
insulated quick disconnect (spade) terminals. For 1/4" spades use
19001-0001 (male) and 19002-0001 (female) for 18-22 AWG wires. (If
the wire is smaller than 22AWG double it over before crimping.) If you
need 14-16 AWG use 19001-0006 and 19002-0024. They're available through
Digi-Key and Mouser, probably lots of other places as well.
If you want to get away from spade type terminals
I've seen ring terminals used. For example JPI supplies small
ring terminals that get crimped on the probe leads and on the wires that
attach to the probes. Their recommended method of joining two ring
terminals is to use a 4-40 screw and nut with a star washer placed between
the two terminals. (See page 5 of http://www.jpinstruments.com/slim_install_primary%20_rev%202.PDF)
The connection is usually covered with some type of fire sleeve. This type
of connection seems to hold up quite well.
Tom Gourley
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