Automotive wire connectors
have many shapes and sizes but one of the most useful I have found is the weather pack connector or Delphi Packard Weatherpack. They come with 1,2,3,4 or 6 conductors, there is also a round 5 conductor and a square 4 conductor. These automotive wire connectors are used in GM vehicles but are very common in the after market due to their ease of assembly and the fact that they are reusable. The terminals are easy to remove and reconfigure to your needs. Weather packs are dirt and water resistant. The max recommended current for a weather pack is 30 amps. Terminals for these connectors range from 22 to 12 gauge.
How to crimp a weather pack connector terminal.
First thing to do when crimping a weather pack terminal is to select the correct gage terminal for the wire being used. Weatherpack terminals are available in 22-18 gauge, 16-14 gauge and 12 gauge sizes. You will also need a wire seal for each terminal. The seals come in different sizes and are color coded for different wire gage size. Green is for 20-18 gauge Grey is for 16-14 gauge and Blue is for 12 Gauge wire.
Next position the cable seal flush with the wire insulation, leaving the striped portion of the wire exposed.
Now place the end of the wire into the terminal and ensure that the seal is lined up with the tangs at the end of the terminal. If the wire is striped to the correct length the copper strands should just be just shy of entering the tubular part of the terminal.
Hold the wire and terminal together and place into the correct crimping slot in the tool. The copper strands are crimped first. Note the pockets in the tool how they form the wings of the terminal in the pictures.
This is how a finished terminal crimp should look like.
The crimping is complete just slide the terminal into the weathpack connector until it clicks into place and then snap the retainer down over the rear of the connector.