Advise please on attaching end terminals to AAW 6 gauge wire

[NorCalC20LWB]

Seems to be a few posts about rewiring these days, here's another. Am in the middle of installing the AAW Classic Update kit to my '72 and it appears AAW is closed for now, so no tech help. Pretty straightforward for the most part, but for me intimidating as all H*ll.

Question is, I'm doing the engine harness section now and the end terminals are larger than the rest of the kit. Some of the wires are 12 gauge, the crimpers I got from them on their rental program work ok for those. But, no way will they work for installing the 6 gauge terminals. Any suggestions/advise is greatly appreciated.

Here's the wire:

[Richard2112]

Put the terminal end in a vice after skinning the wire back as much as you need to inset. Heat the terminal end and melt solder into it. Keep the solder in a liquid state and push the wire into the pool of solder while its hot.

[NorCalC20LWB]

Thanks Richard, so you're saying the terminals do not need to be crimped at all, only soldered?

[Richard2112]

I've done it with copper terminal ends and it worked fine for years without crimping. Your mileage may vary. The larger wires I tend to solder in place. It's just a suggestion. Someone else may have different thoughts on this. There is a solder vs crimp crowd out there.

[MDPotter]

I did exactly as Richard noted, but did crimp it. AAW sells a crimping tool, it's basically just a piece of machined aluminum with different slots in it for sizes of wire. Necessary? Probably not. But it came with my battery cable kit so I used it.

https://www.summitracing.com/parts/aww-500665

[REDROCKER652002]

I think I used a regular crimper on those. I don't have any soldering stuff, so I think I just clamped down on it and made sure it was secure. If you are good with soldering, I am sure that is a much better way to go, I just did not have that option.

[NorCalC20LWB]

Could it be I'm overthinking this?? Sounds like from the responses it's not rocket science, crimp or solder, or crimp and solder, all will work. Maybe the best solution is to crimp it in a vice first then apply some solder, that seems safest.

[Richard2112]

Originally Posted by NorCalC20LWB

Could it be I'm overthinking this?? Sounds like from the responses it's not rocket science, crimp or solder, or crimp and solder, all will work. Maybe the best solution is to crimp it in a vice first then apply some solder, that seems safest.

Your advantage to soldering on a heavy gauge wire is that the strands in the wire are generally thicker than a light gauge and do not withstand bending as much without fraying. The solder will combine the group of strands into one at the connection and generally ensure more surface area contact inside the terminal. But a crimp may be just fine. I find that filling with solder is quick and easy.

[54blackhornet]

You can also use a professional electrician type crimper. I have a friend who is one and his is about three feet long. It has the torque needed to crimp even larger size cables and lugs then shown.

[The Rocknrod]

I vote for Richards suggestion.

[Richard2112]

Originally Posted by The Rocknrod

I vote for Richards suggestion.

thank you. In turn, I endorse yours

[NorCalC20LWB]

54BH, the professional style crimper sounds like an efficient, quick method, but I don't have that option. Sounds like soldering is the best way to go without special tools.

[HO455]

Bingo! Although if you can do a partial crimp it will hold the terminal in place before you begin.

[Pontiac1976]

I do not know if your using Heat shrink or not But it can make it look better help keep the air & water off the soldered and the or any copper wire strands exposed to make longer lasting good connections. A heat gun works much better then open flame for smooth Kool look. Do not forget to put on the heat shrink tube on befor the terminal push it far away on the wire the heat from soldering. So it does not start to shrink be for your ready for it.

[NorCalC20LWB]

Great information from everybody, thanks. Replacing the wiring harness can be overwhelming if you're not very familiar with how these old trucks are wired. Taking it a step at a time starts to build confidence, and the AAW kit makes it easier to understand.

Took the suggestion above and bought this tool from Summit, so a quick crimp, add solder, and apply heat shrink. I don't have a heat gun but pretty sure the little woman's blow dryer should do the trick. It's starting to be kinda fun!

https://www.summitracing.com/parts/aww-500665