How to Repair a Broken Connection with Wire Lugs

By will_owen on 02/15/2018

Broken wire connection

Repairing a Damaged Electrical Wire Connection

Did you know that wires are one of the most easily damaged pieces of equipment that you can use? They can be pinched, frayed, or broken. Too much pressure or bending in a sharp direction can cause it to stop working. This can happen more than you think with power tools, lighting, and more. But instead of having you buy new wires, in this blog, we are going to show you ways in which you can restore a broken connection with a wire lug or wire connector.

Before beginning any wiring process be sure to unplug the electrical device.

Step 1:

You are first going to want to strip off the insulation from the wire using a wire stripper. Be sure to avoid using a knife or wire cutter during this process as it can damage the wire strands within the insulation and be dangerous to the user.

Stripping wire with wire stripper

Step 2:

Place the wire in the right size stripping hole of the wire stripper. The holes are generally measured using gauges, so the higher the gauge the smaller the hole. If you use a stripping hole that is too small you may end up pulling wire strands along with the insulation.

Klein Tools wire stripper

Step 3:

Using a wire stripper strip off a ¼ inch of insulation for crimp wire connectors and 5/8 inch when using alumiconn. Once the insulation is removed you are ready to re-attach the wires.

wire stripped and ready

Step 4:

There are three different wire lugs to use:

Crimp wire connectors are designed for wires that don’t give you enough slack. Place one of the recently stripped wire ends into the connector and use a crimping tool or pliers to tighten the wire. Repeat this process for the other end. If you want to prevent water damage for this wiring, use a heat shrink tube placed over the connector and shrink it with a hairdryer or heat gun.

Blue Crimp Connector

Twist-on connectors use a pigtail twist to make a connection between two wires. If you want to prevent water from entering you need to use silicon.

gray twist-on connector

Alumiconn connectors also use a pigtail twist to make a connection. Just be sure not to tighten too hard on the screws that act as conductors.

2 prong alumiconn


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