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I have been flying for two years with crimped terminals, Molex connectors,
"wrist" connectors, and D-subs. Almost all the terminals are aircraft quality
insulated slip-on or ring. Some are automotive. The one for wires larger than
8-gauge were "crimped" with a hammer-driven tool. None have failed.
Most wires reach their terminal out of a bundle which provides mutual support
so that vibration is not much of a problem.
The only 2 terminal problems I have had were (1) repeatedly losing alternator
output to the B-lead because the wire terminal work hardened and broke off
from vibration -- I finally discovered that the last support for the wire
vibrated differently than the alternator; and (2) The nut securing the battery
terminal to the master relay was coming loose.
Scott Krueger
N92EX
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