How to Repair a Broken Connection with Wire Lugs

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

Recommended Reading

Old homes typically use aluminum wiring, which can cause electrical hazards. Save money on rewiring by opting for electrical connectors.

Homes built before 1970 typically use aluminum wiring, which causes several problems. AlumiConn Aluminum to Copper lugs allow you to repair aluminum wiring without the costly process of rewiring.

Wago connectors make it easy to splice wires together and replace terminal strips and junction boxes. Read our guide to learn about the different types of connectors and the NEC requirements.

While we recommend contacting an electrician for any electrical repair, this guide can help you follow along to see what steps they may take to install an AlumiConn Aluminum to Copper Lug. Use the lugs in accordance with local and national electrical code.

Will Owen
Will Owen

B.A. in English from Kennesaw State University. Will takes what he's learned and writes about all sorts of things from artists to electrical supplies and LED light systems. You name it and he can probably write about it.

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