1. CRIMPING Introduction
This presentation is the companion to “Background / Resources / Crimping Guide” slide show
For more detailed instructions, watch the slide show

2. CRIMPING Overview In this presentation you will learn:
How to use crimping pliers
How to create custom cables and connectors for Vex
How to determine your cable / connector needs
In this presentation you will make:
A 7½ foot motor extension cable
Will connect a motor to the Vex microcontroller

3. CRIMPING Making custom cables
Why?
Standard Vex cables are limited
Might need different lengths
Might need more extension wires than included in your kit
How?
Manufacturing your own cable is simple!
You will use a crimping tool

4. CRIMPING Determine your needs
Ask yourself:
What are you trying to do?
What materials do you have or need?
What is the configuration of the cable needed to complete your task?
What length of cable do you need?

5. CRIMPING Gather tools You will need: Crimping tool
Molex Hand Crimper
Supports 22 – 24 and – 36 AWG
Wire strippers
Tape measure

6. CRIMPING Gather materials
Vex cable parts:
22 AWG wire, 3 conductor cable
Male Molex pins
Female Molex pins
Crimp housing

7. CRIMPING Gather materials
More on your cable:
AWG (American Wire Gauge) is simply a measure of the wire’s thickness
Notice the conductor cable has 3 wires inside (all 22 AWG)
This type of cable is used for input and output in the Vex system
If you do not have this wire available, substitute with 3 (22 AWG) differently colored wires

8. CRIMPING Prepare the cable
Measure the length of cable you need
Make sure to leave yourself 6” of extra length, in case of a mistake
For this example, we need a cable 7½ feet long; so it should be 8 feet total after adding the 6 inches
If your cable needs to be a more exact length, be very accurate; once the pins have been locked into position, they cannot be removed

9. CRIMPING Cut cable Cut the length of cable you measured
Wire strippers usually double as wire cutters; look for a cutting edge on the blade

10. CRIMPING Separate wires
Use wire strippers to remove 1/8” of insulation from each conductor (wire)
Make sure to leave 1½ inches from the end so that you can strip them
This cable has PVC tubing around the three wires (the grey covering)
Trim this PVC covering 1½ inches around the three wires
After trimming the covering, separate the three wires manually

11. CRIMPING Strip wires
Use wire strippers to remove 1/8” of insulation from each conductor (wire)
Make sure to place the wire into the proper gauge hole in your wire strippers
Squeeze handles until the wire strippers bite through the insulation
Slide insulation off the end of the wire, leaving the metal conductor exposed

12. CRIMPING Step 1 We will now begin making the Vex connector
Become familiar with your crimper
Make sure you know how to squeeze the handles until the crimper unlocks

13. CRIMPING Step 1 continued
Use the gauge guide (shown at right) to determine which site to use for your gauge of wire
In our case, we must use site A (because we have been using 22 AWG wire)

14. CRIMPING Step 2
The crimper holds the pin in place for you during crimping
Locate the spring loaded clamp below the jaw of the crimper
Raise the clamp with your finger, as shown

15. Connects wire to Vex microcontroller
CRIMPING Pins
Male pins plug into female pins
For our example, we want our wire to connect the Vex microcontroller and a motor
Male
Female
Connects wire to Vex microcontroller
Connects wire to motor

16. CRIMPING Step 3 Choose a gender of pin for this connector
Place the pin into the open slot on the crimper while the clamp is raised
- The male or female end goes in first
- The pin cradle should face up or open upward

17. CRIMPING Step 3 continued
The pin should move forward until the front of the pin cradle is against the spring loaded clamp
properly loaded pin

18. CRIMPING Step 4 Release the spring loaded clamp
This will lock the pin in position
The pin is designed to fit into this crimper
- If your pin is crooked, or if the clamp does not clamp down properly, simply lift up the clamp and try again

19. CRIMPING Step 5
Notice that there are “teeth” on both male and female pins
The wire must be positioned using these teeth as guides
- Inner set of teeth should be over exposed metal wire
- Outer set of teeth should be over insulation
Inner teeth: close around bare wire
Outer teeth: close around insulation

20. CRIMPING Step 5 continued
Using the guides in the first part of step 5, place the wire in pin cradle, as shown
- The bare wire should touch the clamp

21. CRIMPING Step 6
Squeeze the crimper’s handles to secure the wire into the pin
- Make sure to hold the wire steady so that does not move while crimping
- Squeeze the handles until you feel them release

22. CRIMPING Step 7 Remove the wire from the crimper
- Push on the bottom of the clamp to release the pin
- Once you have reached this state, you cannot separate the wire from the pin without cutting the wire

23. CRIMPING Step 8
Repeat the steps 1 through 7 for each of the two remaining wires, as shown
- Use the same gender pins on all three wires

24. CRIMPING Housing A crimping housing unit is shown at the right
- Once the pins have been inserted into the housing, they cannot be removed
- Pins only fit one way into this particular housing unit
- Both male and female pins can fit into this particular housing unit
Insert pins here

25. CRIMPING Step 9 Place the wires in the crimping housing
- The wires must go in order by color, as shown: black, red, and white
- Once you complete this step, you will not be able to remove the wires from the crimping housing without cutting them

26. CRIMPING Step 10 Line up the wire with the housing
- Make sure the locking tab on the pin cradle is facing up, as shown

27. CRIMPING Step 10 continued
Slide the pin into the housing, as shown, until the pin is locked into position
- Do not force the wire
- The pin might make a clicking sound when it has locked into position

28. CRIMPING Step 10 continued
To test if your pin is locked into the crimp housing, gently tug on the wire, as shown

29. CRIMPING Step 11 Insert the remaining pins into the housing
- Remember the order of colors: black, red, white

30. CRIMPING Step 12
Repeat steps 1 through 12 for the other side of the wire
Check your completed connector against the official Vex connector

31. CRIMPING Testing Connect the female connector to the motor
Connect the male connector to the Vex microcontroller
Be sure not to insert these wires backwards; refer to the pictures at the right
Turn on your robot and test the motor with your radio control transmitter