TIL a lot of folks are still using the wrong crimp die for the MS25036 connectors on our comms harnesses.

I've seen three separate harnesses from different shops this month where someone used a standard D-609 die instead of the specific four-indent MS1788 die, which creates a weak point that can fail vibration testing, so has anyone else found a good way to spot-check this before a harness goes into the bird?

3 comments

3 Comments

the_pat1mo ago

Man, I used to believe a crimp was just a crimp if it held the wire. Reading this makes me realize how wrong that is. A weak point from the wrong die could mean real trouble down the line. How do you even check for the right indent pattern without taking the whole thing apart? Seems like a visual guide or a simple gauge at the bench would be a lifesaver.

the_lee1mo ago

Ever notice how many things in life are like that? The right tool for the job seems obvious, but people grab the almost-right thing to save a minute. You see it with people using the wrong screwdriver head and stripping a screw, or the wrong cleaner on a surface. That tiny shortcut builds in a weak spot that shows up later, every single time.

grant.sam1mo ago

Yikes, that's a serious find. I read a tech memo that said the wrong die leaves a smooth, rounded crimp instead of the four sharp indents. @the_pat is right, a simple go/no-go gauge at the bench for those indents would catch it fast before it gets built up.