Electrical Hardware Master Guide – Hudson Valley MRO Reference

TABLE OF CONTENTS

• Electrical Terminals
• Wire
• Connectors & Fasteners
• Wiring Devices
• Battery

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Electrical Terminals  – Hudson Valley MRO Reference

Nylon-insulated crimp terminals are used to create a secure, low-voltage electrical connection between a wire and a stud, screw, or other terminal point. MRO mechanics in Kingston, N.Y. rely on these terminals because the copper-alloy barrel forms the actual electrical path while the tin-plated surface resists corrosion in daily service. The smooth, burr-free interior keeps the conductor intact during crimping, and the funnel-shaped entry guides the wire straight into the barrel for consistent, repeatable terminations.

The nylon insulation sleeve adds structural support around the barrel. It helps the terminal withstand vibration, solvents, and abrasion while maintaining its shape under heat up to 105°C. Moisture resistance also increases the dielectric strength of the joint. Color-coded sleeves make wire-size identification straightforward during assembly or repair work.

These terminals use a double-crimp system. The first crimp compresses the conductor inside the metal barrel to create the electrical bond. The second crimp grips the wire’s insulation. This second crimp acts as strain relief, reducing movement at the entry point and preventing the conductor from flexing or pulling loose under vibration.

The combination of copper alloy, tin plating, and nylon insulation provides both mechanical and electrical stability. The copper barrel handles the current, while the insulation and strain-relief crimp manage the mechanical load. This separation reduces failures caused by pulling, bending, or constant motion.

UL and CSA ratings verify that the terminals meet the required temperature and wire-range specifications. The construction helps prevent common problems such as frayed strands, loose wires, broken terminations, and pull-outs in circuits exposed to heat, movement, or repeated service.

Chamfered lead-ins support smooth wire entry, and the molded nylon sleeve keeps the conductor aligned and supported during and after installation. The double-crimp design spreads stress across the terminal, improving reliability in demanding electrical circuits.

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Solder & Seal terminals combine a heat-shrink sleeve, a built-in solder ring, and an adhesive liner to create a sealed electrical splice. When heat is applied, the sleeve shrinks, the solder melts into the conductors, and the adhesive bonds to the insulation. The result is a weather-resistant joint designed to keep out moisture, dirt, and vibration.

These connectors differ from standard crimp terminals because the electrical bond is formed by solder, not by compressing a metal barrel. The shrink tubing provides the mechanical support. When the solder ring melts, it flows into the exposed wire ends to form the splice. Once cooled, the adhesive seals the joint and prevents contaminants from reaching the conductors.

Pull-out strength and tensile ratings vary based on construction. Standard crimps without adhesive test around 40 lbs, and heat-shrink lugs with adhesive near 45 lbs. A Solder ’N Seal splice typically measures around 16 lbs of pull-out and about 25 lbs in tensile testing. These values reflect the design: the joint depends on solder and shrink tubing rather than a crimped barrel.

UL recognition applies to specific parts, such as butt connectors under File E125694 and ring and spade terminals under File E141071. CSA certification covers full connector sets under File 100774. These listings confirm that the components meet established electrical and mechanical requirements.

Installation relies on controlled heating. The process includes stripping the wire, sliding the connector into place, overlapping the conductors inside the solder ring, and applying heat until the solder flows. Each connector contains a fixed amount of solder to ensure repeatable results. A heat gun is recommended to deliver even heat so the solder melts correctly and the tubing seals fully.

Industry guidelines note that soldered splices are often recommended for low-current circuits, such as sensor or computer wiring, where small resistance changes can cause problems. Proper sealing is important to prevent corrosion, which can lead to signal loss over time.

When installed correctly, a Solder & Seal terminal forms a sealed, moisture-resistant splice that protects the connection from weather, vibration, and long-term degradation.

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Multilink terminals combine three connection methods in one piece: a mechanical crimp, a solder element, and an adhesive-lined heat-shrink sleeve. The design allows the joint to be reinforced in stages as heat is applied, creating both electrical continuity and a sealed outer barrier.

The crimp section uses a zipper-braze seam that forms a solid, uniform barrel when compressed. A small inspection window allows the conductor position to be checked before crimping, and a built-in wire stop prevents the conductor from being pushed too far into the terminal. Serrations inside the barrel help grip the strands, improving mechanical hold after the crimp is set.

The solder element is a low-temperature alloy with flux already applied. The flux removes surface oxidation during heating, and the pre-measured solder pellet melts into the strands once the temperature is reached. This fixed solder quantity keeps the joint consistent and helps fill the conductor interface without relying on external solder.

The outer tubing is adhesive-lined polyolefin heat-shrink. When heated, it contracts around the connection and the adhesive bonds to the insulation, sealing out moisture and debris. The tubing is color-coded for quick wire-gauge identification and remains translucent so the crimp and solder flow can be visually confirmed during installation.

When assembled correctly, a Multilink terminal delivers a mechanical crimp, a soldered electrical bond, and a sealed heat-shrink barrier in a single piece, producing a reinforced connection for wiring exposed to movement, moisture, or changing temperatures.

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This style of splice combines three elements in one piece: a mechanical crimp, a soldered bond, and a sealed heat-shrink covering. The design follows long-standing industry requirements calling for connections that are mechanically secure, electrically solid, and protected from moisture or corrosion.

The crimp connector uses a brazed seam to create a strong mechanical hold on the conductor. This forms the first stage of the joint and keeps the strands stable during heating. The solder portion contains a low-temperature alloy with built-in flux, allowing the solder to melt evenly into the wire and create a uniform electrical bond with improved current flow and tensile strength.

Around the outside, translucent adhesive-lined heat-shrink provides the final seal. When heated, the tube contracts around the splice and the internal adhesive bonds to the insulation. This creates a moisture-resistant barrier while still allowing visual confirmation of both the crimp and the solder flow.

When all three steps—crimping, soldering, and sealing—are completed, the connection meets demanding reliability standards and protects the splice from vibration, weather, and long-term corrosion.

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A butt connector joins two wire ends in a straight line. The process starts by stripping each wire about 3/8″ and choosing a connector that matches the wire gauge. Each conductor is pushed into the barrel until it reaches the internal stop. Positioning the seam upward helps the crimp tool compress the barrel correctly. After the crimp is made, the color band on the connector confirms that the crimp was placed in the correct zone.

Once the mechanical crimp is finished, heat is applied to the center of the connector. The solder ring inside melts and flows into the strands, forming the electrical bond. Heat is then moved to the ends so the tubing shrinks and the adhesive seals to the insulation. Allowing the connection to cool without movement helps the solder solidify and the adhesive set, completing the splice.

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Ring, spade, and slip-on terminals use the same basic preparation steps as other sealed connectors. The wire is stripped about 1/2″, and the conductor is inserted so the insulation enters the metal barrel. This allows the crimp to grab both the copper strands and the insulation, giving the joint mechanical support. The correct die is used to form a solid crimp on each section of the barrel.

After crimping, heat is applied to the solder ring built into the connector. Once the solder melts, it flows into the exposed strands and forms the electrical bond. Heating then continues outward from the center until the heat-shrink tubing contracts evenly and the adhesive seals to the wire insulation at both ends. When the joint is fully shrunk and the adhesive has flowed, the terminal is left to cool so the seal and solder can set.

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Step-down butt connectors are used when two wires of different sizes need to be joined in a straight splice. Each end of the connector is sized for a specific wire gauge, and the stripes on the tubing act as guides so each conductor is inserted and crimped on the correct side.

Unlike some step-down connectors that look the same on both ends, the Multilink version uses different inside and outside diameters. This makes the small-wire end easy to recognize and helps prevent the common mistake of placing the larger conductor into the smaller barrel. The diameter change also improves mechanical retention by matching each wire to a correctly sized crimp section.

These connectors are available in uninsulated, Shrink ’N Seal, and full crimp-and-solder sealed versions. The two-stripe system marks both insertion depth and crimp-die selection. The larger wire aligns with the blue stripe, and the smaller wire aligns with the yellow stripe. This clear marking reduces confusion when transitioning between wire sizes such as 14–16 / 10–12 AWG and 18–22 AWG.

With the correct orientation, each side of the connector is crimped with the proper die, improving strength and uniformity. The visual cues help prevent mis-crimping and support consistent performance when the splice is exposed to vibration, pull forces, or repeated movement.

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A quick-change ratcheting terminal crimping kit is a multi-purpose tool system designed to handle many different terminal types by swapping dies instead of using separate crimp tools. The steel ratcheting frame delivers consistent pressure, and the interchangeable dies lock into place so each terminal style is crimped with the shape it requires. The kit is stored in a molded case that organizes the dies and provides a portable layout for field work.

The die sets cover insulated terminals in the 22–10 AWG range and non-insulated open-barrel connectors in the same wire sizes, including weather-resistant versions. The kit also supports fully insulated quick-disconnect terminals, crimp-only styles, and both insulated and non-insulated flag terminals across various small-gauge ranges. Each die is shaped to match the geometry of the terminal type it is intended to crimp.

One of the dies is dedicated to spark-plug wire terminations. This die handles both the conductor crimp and the insulation crimp in one motion. The process involves stripping the wire, placing the terminal over the core, and using the die to form the spiral crimp pattern required for spark-plug wire assemblies.

Using a matched die for each terminal type improves the accuracy and repeatability of the crimp. Proper die selection ensures that the conductor is shaped correctly, the insulation support is formed as intended, and the finished connection maintains good electrical contact and mechanical stability.

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A professional ratchet crimping tool is designed to create a consistent, controlled crimp on heat-shrink terminals. The ratcheting mechanism applies even pressure through the full stroke, which helps form a repeatable connection without crushing the terminal or under-crimping it. The handles are shaped to reduce hand strain during repeated use.

The crimp nests are sized for common heat-shrink terminal groups. The tool includes positions for 8–22 AWG (red), 16–14 AWG (blue), and 12–10 AWG (yellow), along with a second red nest for 22–18 AWG terminals. Each nest matches the insulation diameter and barrel size for its range, allowing the terminal to be compressed evenly around the conductor.

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A micro torch is a small, handheld heat source used for tasks that require controlled, concentrated flame. Its compact size makes it easy to carry, and some designs include clips so it can be attached to a pocket, tool bag, or keychain. The torch runs on butane fuel and can operate anywhere from about 30 minutes to 2 hours depending on the flame setting.

The flame temperature ranges roughly from 1300°F to 2400°F, allowing the tool to handle heat-shrink tubing, light soldering, and other small electrical or mechanical jobs that need precise heating. Its dimensions—about 1-3/8 inches wide and 2-3/4 inches high—keep it portable while still producing enough heat for field repairs or bench work.

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A mini torch provides controlled heat for small repair and assembly tasks. It is commonly used for shrinking tubing, activating adhesives, softening plastics for bending, and performing light soldering. The focused heat also works for jobs like drying damp components or thawing frozen locks.

The torch operates on butane fuel and uses a flameless heating method, which helps direct heat without producing an open flame. It reaches temperatures up to about 650°C (1300°F), giving it enough output to handle most heat-shrink and light-duty soldering work. A heat reflector is included for use with heat-shrink terminals, helping concentrate the heat around the connection for more even shrinking and sealing.

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E-Z View butt connectors are designed to solve visibility problems that occur with standard heat-shrink connectors. Traditional opaque insulation makes it hard to see where the conductor is positioned inside the barrel. When the wire stops short or twists out of place, the crimp may land on the wrong spot, reducing both mechanical grip and electrical contact. Color stripes normally show wire-gauge size, but they do not show where the conductor should sit before crimping.

The E-Z View design uses a transparent insulation window so the conductor can be seen during assembly. This makes it possible to confirm that the wire is centered in the connector and fully inserted before crimping. The clear sleeve also shows the crimp location, helping ensure the tool compresses the barrel directly over the conductor rather than over empty space.

Each connector includes a built-in wire stop to prevent over-insertion. With the conductor visible against the stop, the installer can confirm proper seating and alignment before applying the crimp. The waterproof insulation allows inspection throughout the installation and helps maintain a sealed joint once heat is applied.

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Clear-View heat-shrink tubing is made from a cross-linked ionic polymer that provides good structural strength while staying lightweight and easy to cut. The tubing is marked with the applicable AWG range, making size selection straightforward during electrical repair or assembly work.

The inside of the tubing is coated with a hot-melt adhesive. As the tubing heats and shrinks, the adhesive flows and bonds to the wire insulation, creating a waterproof seal. This seal helps protect the splice from moisture, dirt, and environmental exposure common in field wiring conditions.

The tubing offers more than a 2.5:1 shrink ratio, allowing it to slide over larger connectors or wire bundles and still contract tightly around the finished joint. It can shrink by as much as 2 inches in length while maintaining coverage. The clear construction allows visual inspection of the connection after installation, confirming proper seating, solder flow (if used), and full adhesive sealing.

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Clear-View heat-shrink tubing is built from a cross-linked ionic polymer, giving it strength and stability once shrunk. The material provides a shrink ratio greater than 2.5:1, allowing it to fit over larger components and still tighten securely around the finished joint.

The tubing begins shrinking at about 90°C (194°F) and is rated for continuous use from –55°C to 125°C (–67°F to 257°F). It also passes FMVSS 302 flammability requirements, indicating a burn rate of less than 100 mm/min. Longitudinal change during shrinking ranges from 1% to 10%, which helps the tubing maintain coverage without excessive shortening.

Dielectric strength is rated at 750 V/mil (30 kV/mm), providing strong electrical insulation once installed.

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Shrink & Seal terminals use a dual-walled, adhesive-lined splice designed to create a sealed electrical connection. The inner adhesive is a polyamide compound with high dielectric strength. When heated, the adhesive bonds to the wire insulation and forms a moisture-resistant barrier, protecting the joint from corrosion and environmental exposure. A flexible strain-relief sleeve helps support the conductor once the splice is complete.

The outer sleeve is made from radiation-cross-linked polyolefin that meets the dimensional requirements of MIL-I-23053/4, a common military-grade specification for heat-shrinkable tubing. The material remains stable under heat and has a controlled “hot-tear” strength, meaning it can be crimped without the sleeve splitting or degrading during installation.

During heating, the clear tubing shrinks uniformly around the connector. This pulls the adhesive into contact with the insulation and forms a single sealed splice. The transparent material allows the crimp area to remain visible until the tubing has fully contracted. Once cooled, the splice combines mechanical grip, electrical continuity, and a sealed outer shell designed to maintain long-term integrity.

Shrink & Seal terminals are used anywhere a sealed, strain-relieved electrical splice is needed. Typical applications include automotive and truck wiring, trailers, RV systems, marine wiring, air-conditioning equipment, construction machinery, outdoor lighting, sprinkler systems, telecommunications lines, and general industrial maintenance. These environments often expose wiring to moisture, vibration, and temperature changes, making a sealed splice important for long-term reliability.

Installation starts by selecting the correct terminal size for the wire gauge. The wire is stripped so the bare conductor sits centered inside the crimp barrel. Once positioned, the barrel is compressed using the correct die. A solder ring is located in the mid-section of the connector, and heat is applied directly to this area. As the temperature rises, the solder melts and flows into the conductor strands, forming the electrical bond.

After the solder has flowed, heating continues along the sleeve. The adhesive-lined polyolefin shrinks around the splice, bonding to the insulation and encapsulating the entire joint. The tubing remains flexible as it cools, creating a sealed repair that protects against moisture and mechanical stress. The funnel entry on the barrel helps guide the conductor into place, reducing stray strands and improving alignment before crimping.

The design includes a nylon insulation grip around the barrel to support the conductor and provide strain relief. This reduces tension on the wire during equipment movement or vibration. The sleeve is soft, heat-stabilized, and engineered to maintain flexibility after installation.

Compliance information lists approvals from Underwriter Laboratories and the Canadian Standards Association, along with U.S. military specifications such as QQB 575C, CSS, and related MIL-spec requirements. These standards cover the dimensional accuracy, sealing behavior, and performance characteristics necessary for reliable splicing in demanding electrical systems.

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Flared vinyl-insulated crimp terminals and disconnects are designed for general electrical connections where a durable insulated joint is needed. The vinyl insulation is color-coded for standard wire-gauge ranges: red for 22–18 AWG, blue for 16–14 AWG, and yellow for 12–10 AWG. The metal bodies are made from copper, with lighter red 22-18 gauges constructed from 0.032″ copper and heavier blue 16-14 & yellow 12-10 gauges from 0.040″ copper to match the mechanical load of each wire size.

The terminals use a butted-seam barrel designed to stay closed under full crimping pressure. This helps prevent the barrel from splitting during installation. Inside the barrel, serrations grip the conductor strands firmly. These serrations provide mechanical retention and help maintain low electrical resistance by keeping the strands tightly compressed. The serration detail is repeated in the source material and reflects the importance of this feature.

The shouldered barrel positions the terminal properly in the crimp tool, helping create a uniform crimp. The flared entry at the insulation side allows various insulation thicknesses to fit into the terminal cleanly. This expanded entry provides support once the crimp is formed, helping stabilize the wire and reducing strain at the insulation edge. The construction is aimed at producing a secure mechanical hold with a stable electrical path.

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Vinyl-insulated step-down butt connectors are used when two wires need to join into one side of a splice, with a single wire exiting the other side. The connector has different internal diameters on each end, allowing conductors of different gauges to be matched and secured in a single splice. This stepped design is shown in the source cutaway and is the key feature that separates these connectors from standard straight butt splices.

The insulation is flared vinyl, which helps guide wires of different outer diameters into the barrel. The flared design also supports the insulation after the crimp is formed. A color-coded stripe is printed near the step-down end. This marking identifies the correct orientation so the larger or combined conductors are inserted into the proper side of the connector.

The stepped internal diameter maintains a firm mechanical grip on each wire size once crimped. This allows the splice to hold wires securely even when their gauges differ. The color stripe acts as a clear reference point during installation, reducing the chance of inserting a conductor into the wrong end and ensuring the crimp is applied where the barrel is designed to compress correctly.

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High-temperature non-insulated terminals are designed for electrical connections exposed to extreme heat. Instead of the copper used in standard terminals, these versions are made from alloy steel, which maintains its strength and shape at elevated temperatures. A nickel-plated finish is applied to the surface to resist oxidation and provide stability when the metal is repeatedly heated.

These terminals are rated for continuous use between 900°F and 1200°F, making them suitable for locations where standard terminals would soften, scale, or lose mechanical grip. Although their base metal is different, the terminals follow the same general dimensions as standard non-insulated types, allowing them to fit familiar studs, screws, and wire layouts.

The available wire ranges include 22–18 AWG, 16–14 AWG, and 12–10 AWG. In high-heat electrical assemblies—such as near exhaust components, heaters, industrial ovens, or machinery with constant thermal cycling—these alloy-steel terminals provide a stable mechanical and electrical connection where normal terminals would fail.

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Non-insulated solderless terminals are basic crimp-style connectors made from soft annealed electrolytic copper. This copper provides high electrical conductivity and enough ductility for the barrel to compress evenly around the wire during crimping. To protect the metal from oxidation and surface wear, the terminals are coated with electro-tin plating, which improves corrosion resistance without affecting conductivity.

These terminals are intended for general-purpose electrical connections where insulation is not required on the terminal itself. They maintain a simple metal-to-metal interface and rely entirely on the crimp for mechanical grip and electrical continuity. The available wire ranges include 22–18 AWG and 16–14 AWG. Their straightforward construction makes them suitable for controlled environments, protected junction points, and applications where insulation or sealing is handled separately from the terminal.

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Uninsulated step-down connectors are used to splice two different wire gauges in a single crimp-style connection. These connectors do not include sealing or heat-shrink protection, so they are intended for dry or protected locations where the splice does not require environmental shielding. The stepped barrel design allows one end to accept a smaller wire and the other end to accept a larger wire, creating a secure transition between the two sizes once crimped.

Each connector is marked with a color stripe that identifies the wire-gauge pairing. The white-striped version joins 24–22 AWG to 18–16 AWG. The red-striped version joins 20–18 AWG to 16–14 AWG. The blue-striped version connects 16–14 AWG to 12–10 AWG. The yellow-striped version joins 12–10 AWG to 8 AWG. These markings provide a quick visual reference so the correct end is matched to the correct conductor.

The crimp type used on each side matches the wire gauge inserted into that end. Because the barrels are not insulated or sealed, the mechanical grip and electrical continuity depend entirely on proper die selection and correct crimp placement. When used in the appropriate environment, these connectors provide a straightforward method for splicing dissimilar wire sizes in a compact, metal-only termination.

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Quick-disconnect adapters are used when a 0.250-inch male terminal must be extended, split, or re-routed without cutting into the harness or altering the original terminal. Each adapter changes only the mechanical connection layout. No electrical performance claims are made beyond the physical interface.

“Y” Adapter accepts two 0.250-inch male terminals and outputs a single 0.250-inch female terminal. Its only verified function is to merge both male terminals into one female connection point. The source provides no statements about load sharing, current behavior, or circuit effects.

Parallel Adapter accepts two 0.250-inch male terminals and provides two 0.250-inch female terminals. It serves as a mechanical extension that preserves a two-male-to-two-female layout. The source gives no information about electrical distribution, so no interpretations about “parallel operation” are added.

Piggy-Back Adapter accepts two 0.250-inch male terminals and supplies one 0.250-inch female terminal. Its purpose is to allow a connection to be stacked when an additional female termination point is needed. The source does not describe any circuit expansion or electrical behavior beyond the physical connection.

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Wire pin terminals are non-insulated connectors used when a straight, solid pin is required for junction blocks, plugs, or terminal strips. They are common in truck and trailer junction boxes and in European-style terminal blocks. 

The 22–18 AWG and 16–14 AWG sizes use a 0.37-inch pin, while the 12–10 AWG size uses a 0.46-inch pin. The barrel grips the conductor, and the solid pin provides a clean connection point for screw clamps or spring terminals that need a firm, non-stranded interface.

Fuse taps create an additional connection point at a blade-style fuse without altering the harness. A standard fuse tap uses a 0.250-inch tab width to match common blade fuses. 

The Minifuse tap adapter accesses power from the hot side of a MINIFUSE by stripping one fuse leg and crimping a fully insulated female quick connector onto the adapter tab. This provides an added termination point while keeping the original wiring intact.

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MATE-N-LOK non-insulated terminals are used in plug-style electrical connectors found in communication equipment, office machines, and control systems. They rely on a crimped barrel for conductor attachment and a built-in retention barb that locks the terminal inside the plastic housing. All versions accept 20–14 AWG wire and use a 0.084-inch pin diameter, with identical electrical and dimensional characteristics across the entire series.

Single-barb terminals use one retention barb to secure the terminal in the connector housing. The single-barb male terminal (Part No. 210170) mates with the single-barb female terminal (Part No. 210171).

Dual-barb terminals use two retention barbs for increased holding strength inside the housing. The dual-barb male terminal (Part No. 210172) mates with the dual-barb female terminal (Part No. 210173). The wire range and pin diameter remain the same; the only difference is the level of mechanical retention provided by the barb design.

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Deutsch DT Series connectors are environmentally sealed connectors used in engines, transmissions, chassis wiring, brake systems, exterior lighting, and cab electronics. Their construction keeps electrical contacts protected from moisture, dirt, vibration, and thermal cycling, making them suitable for harsh operating conditions across fleet, agricultural, and industrial equipment.

DT Series connectors withstand submersion in roughly three feet of water and operate from –55°C to 125°C. The system carries a maximum current rating of 13 amps, matching the terminal and wire size used in this series. The housings are molded from thermoplastic, and silicone elastomer seals protect the contact cavities. A thermoplastic wedge lock holds the terminals in place. The contacts are copper alloy with a nickel finish for corrosion resistance and stable conductivity.

The terminals are designed specifically for DT housings. The female socket terminal fits DT plugs and accepts 16–14 AWG wire. The male pin terminal fits DT receptacles and also accepts 16–14 AWG wire. Proper sealing and terminal retention come from the housing seals and the wedge lock once installed.

The specified crimp tool is the Deutsch hand tool, which forms an eight-indent crimp on the solid contacts. This pattern provides full circumferential compression for mechanical strength and reliable electrical continuity.

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Industrial split bolt connectors are mechanical splicing devices used to join or tap conductors in utility work, plant maintenance, and building construction. They clamp solid or stranded wires between the bolt body and pressure bar, forming a tight, low-resistance joint when properly torqued.

Copper split bolt connectors are made from a high-strength copper alloy and are limited to copper-to-copper applications. The alloy provides the clamping strength needed to secure copper conductors and resists corrosion and seasonal cracking in outdoor or high-humidity environments. 

Precision-machined threads allow the bolt to reach full torque, producing a stable connection that runs cool under load. These connectors are UL Listed and CSA Registered, with wire ranges from 12 str–10 str up to 2/0 str–500 MCM copper conductors.

Aluminum split bolt connectors are made from a heat-treated aluminum alloy and can be used with aluminum conductors or mixed aluminum-and-copper combinations. The design meets 486B testing requirements. 

A triangular-edged pressure bar is used to cut through surface oxides on aluminum conductors during installation, ensuring a clean contact surface and reducing resistance. Wire ranges extend from 10 str–6 str up to 400 MCM–500 MCM conductors.

Both connector types depend on correct conductor pairing and proper torque to create a safe, durable splice in industrial electrical systems.

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Wire – Hudson Valley MRO Reference

PVC general-purpose primary wire uses a stranded copper conductor with thermoplastic PVC insulation. It operates from –30°F to 165°F (–34.4°C to 73.9°C) and resists grease, oil, and acids. Available gauges include 22, 20, 18, 16, 14, 12, 10, and 8 AWG. It meets or exceeds SAE J1128, Ford M1L56-A, Ford M1L58-A, and Chrysler MS-3450.

SXL cross-link primary wire is designed for extreme-temperature automotive locations such as engine compartments. It uses cross-linked polyethylene insulation over a stranded copper conductor and operates from –50°F to 350°F (–45.6°C to 176.7°C). 

It remains stable under heat without melting and resists moisture, solvents, and acids. Available gauges include 18, 16, 14, 12, and 10 AWG. It meets or exceeds SAE J1128, Ford M1L85-A, Chrysler MS-5919, and Packard M-3023.

Electrician shears use high-quality stainless steel blades hardened to 56 HRC. They are designed for clean, non-slip cutting and include an integrated cable cutter. A plastic belt case is supplied for storage and carrying.

Jacketed plastic primary wire is used in automotive, truck, and trailer systems where a protected multi-conductor cable is needed. Fleet MRO mechanics in Poughkeepsie, N.Y. work with this style of wiring because the PVC-insulated primary conductors are laid in parallel and protected by a gray vinyl jacket that holds up in daily service. It is UL1015 listed at 600 volts and meets DOT and Coast Guard electrical requirements.

It is intended strictly for low-voltage 12- and 24-volt systems. The temperature rating is 221°F (105°C) dry and 167°F (75°C) wet. Available sizes include 16/2, 16/3, 16/4, 14/2, 14/3, 14/4, 12/2, 12/3, 10/2, and 10/3. The jacketed construction provides resistance to grease, oil, acids, and gasoline.

UL-listed multi-conductor marine cable is used for boat wiring above and below the waterline. It carries the UL BG5W2 listing at 600 volts and meets Coast Guard requirements for marine cable. The conductors are stranded copper with PVC insulation and a clear all-weather jacket for durability in wet, salt-exposed environments. It is available in two, three, and four conductor configurations and is rated for operation up to 160°F (71.1°C).

Bonded parallel primary wire is used in RVs, boats, and utility trailers. It is UL BG5W2 listed at 600 volts and meets Coast Guard boat-cable specifications. It uses PVC-insulated primary wires laid parallel and covered with a white outer jacket. It is available in two- or three-conductor formats. The temperature rating is 221°F (105°C) dry and 167°F (75°C) wet. Available sizes include 16/3, 14/2, 14/3, 12/2, and 12/3.

Service cord, 300-volt, Type SJ is intended for stationary light-duty service. It is UL listed (E7362) and OSHA acceptable, using a black rubber jacket with rubber-insulated conductors. The temperature range is –35°F to 140°F (–37°C to 60°C). Available sizes include 18/3, 16/3, 14/3, and 12/3.

Service cord, 300-volt, Type SJO is a heavy-duty version used for portable tools, motors, and power extensions. It is UL listed (E7362), OSHA acceptable, and passes the MSHA flame test (P136-MSHA). The construction uses an oil-resistant neoprene jacket with rubber-insulated conductors. The temperature rating is –35°F to 194°F (–37°C to 90°C). Available sizes are 16/3 and 14/3.

Lamp wire, Type SPT-1, is a 300-volt parallel-style wire used for alarms, lamps, and other light-duty circuits. It uses “ripcord” construction with insulation coded for circuit identification. Available sizes are 18/2 and 16/2.

Speaker wire is used for general audio applications in homes, offices, cars, motor homes, and boats. It uses insulated copper conductors in a clear jacket, except for the 22/2 gauge which uses a gray jacket. Polarity coding is included for proper audio phasing. Available sizes range from 22/2 through 12/2.

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Service cord, 600-volt, Type SO is built for heavy-duty service where industrial equipment, heavy tools, battery chargers, portable lights, and power extensions require a durable, flexible supply cable. It is UL listed (E7362), OSHA acceptable, and meets the P136-MSHA standard by passing the MSHA flame test. 

The temperature rating runs from –35°F to 194°F (–37°C to 90°C). The jacket resists oil, acid, impact, abrasion, sunlight, and flame. Standard configurations include 16/3, 14/3, 12/3, and 10/3, with a four-conductor option available by special order.

WELD-FLEX super flexible welding cable uses a rope-stranded conductor made from ultra-thin No. 32 AWG annealed copper for maximum flexibility. It meets all international specifications and is also used for heavy-duty battery and jumper cables. The cable uses a double cover jacket with a PVC inner core and an NBR outer jacket, giving high toughness and resistance to abrasion, oil, heat, ozone, and most solvents. 

The 4, 2, and 1/0 gauge sizes use approximately 660, 1050, and 1670 strands respectively, each with outer diameters of 0.375 inches for 4 and 2 gauge, and 0.450 inches for 1/0. Larger sizes include 2/0 with 259 strands of 0.022-inch wire and a 0.590-inch diameter, and 3/0 with 418 strands of 0.024-inch wire and a 0.740-inch diameter.

Battery cable uses a stranded copper conductor with polyvinyl thermoplastic insulation. The coating resists moisture, weather, acids, and oil. Standard polarity follows black for ground (–) and red for positive (+). The 4-gauge version contains roughly 660 wires and is rated for 162 amps. The 2-gauge version contains roughly 1050 wires and is rated for 279 amps. The 1/0-gauge version contains roughly 1670 wires and is rated for 390 amps.

Trailer light cable is an all-weather, heavy-duty cable for truck and trailer lighting systems. It uses heavy black vinyl insulation and tinned copper conductors that are color-coded and compliant with ATA specification E1-1950 and most SAE standards. The 14-gauge 4-conductor cable uses 19 strands of 27 AWG wire with a 0.410-inch outer diameter. 

The 14-gauge 6-conductor version uses the same strand count with a 0.500-inch diameter. The 14-gauge 7-conductor version also uses 19 strands of 27 AWG with a 0.496-inch diameter. The 12-gauge 6-conductor cable uses 19 strands of 25 AWG wire with a 0.600-inch diameter. The 10-gauge 7-conductor cable uses 19 strands of 23 AWG wire and also measures 0.600 inches in outer diameter.

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Connectors & Fasteners – Hudson Valley MRO Reference

Standard twist-on wire connectors use a flame-retardant thermoplastic shell with a galvanized square-wire internal spring. MRO technicians in Goshen, N.Y. rely on this design because the spring draws the conductors tightly together as the connector is twisted, forming the mechanical joint that keeps circuits stable in everyday service.

The deep skirt protects the insulation, and the threaded entry helps guide the wires for a secure fit. They are UL Listed (E5238), CSA Certified (LR 9706), and can be backed off for re-use when required. The maximum rating is 600 volts for building wire and 1000 volts for fixtures and signs.

Gray connectors handle No. 20 through No. 16 AWG conductors at both the minimum and maximum range.

Blue connectors accept No. 22 through No. 16 AWG at minimum and up to No. 12 through No. 16 AWG at maximum.

Orange connectors accept No. 22 through No. 18 AWG at minimum and up to No. 10 through No. 18 AWG at maximum.

Yellow connectors accept No. 18 through No. 12 AWG at minimum, including combinations such as one No. 14 with one No. 18, and up to No. 10 with two No. 12 at maximum.
Red connectors accept No. 20 through No. 14 AWG at minimum and up to No. 10 with two No. 12 at maximum.

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O/B/R/Y and G Scotchlok connectors are UL Listed for 600 volts and meet UL maximum-fill requirements. Their design combines the torque and wide wire-range capability of a wing-style connector with a self-wiping metal thread that reduces wear and makes re-entry easier. 

Only three connector types are needed to cover most combinations from 22 AWG up to 6 AWG, replacing the work of eight standard connectors. The two-connector models use a refined splice and wing design that allows full wire insertion without requiring extra space in the electrical box.

The 3M Direct Burial Splice Kit is UL listed for direct burial and rated for 600 volts. It uses a gel-filled moisture-proof tube to protect the splice and is built for fast installation with a quick-bite, smooth-twist connector action. 

The small tube diameter makes the assembly compact, and the sealant provides long-term moisture resistance. It is intended for copper conductors only and supports stranded or solid combinations. Typical applications include golf courses, irrigation controls, and outdoor lighting.

Common wire combinations include:
2–7 of #18, 1–3 of #12 with 1 of #18
2–2 of #14 with 1 of #12, 1–2 of #10 with 1 of #12
2–6 of #16 with 1 of #12, 2–4 of #14 with 1 of #12
2–5 of #18 with 1 of #16, 2–3 of #12 with 1 of #10
2–8 of #20 with 1 of #18, 1–2 of #10 with 1 of #8
2–7 of #18, 1–2 of #10 with 1 of #18

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Compact splicing connectors with operating levers are designed for fast, space-efficient splicing of two to five conductors. They use a transparent housing for visual confirmation of conductor seating and are rated for 600 volts in building wiring and 1000 volts in fixture or sign applications. They accept 24–12 AWG solid or stranded conductors within a 0.14–4 mm² range, and 24–12 AWG fine-stranded conductors within a 0.2–4 mm² range. 

The operating levers secure the conductors without tools and provide a dependable hold on solid, stranded, or fine-stranded wire. The connectors are rated for 32 amps continuous current and are designed to minimize installation time while maintaining reliable, safe splicing performance.

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Dryconn waterproof connectors use a silicone-based sealant to protect splices in wet, moist, or humid environments. They are UL listed and CSA certified for wet locations and direct burial. The connectors are twist-on, pre-filled with sealant, and use a square-wire internal spring. They are flame-resistant and corrosion-resistant, with a temperature rating from –40°F to 400°F. All models are rated for 600 volts except the yellow version, which is limited to 300 volts.

Gray connectors accept 20 AWG to 16 AWG conductors and are rated for 600 volts.
Blue connectors accept 20 AWG to 12 AWG conductors and are rated for 600 volts.
Red connectors accept 14 AWG to 8 AWG conductors and are rated for 600 volts.
Yellow connectors accept 14 AWG to 8 AWG conductors and are rated for 300 volts.

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Motor pigtail connectors are used to make fast, reliable change-offs on electric motors and transformers. They use a removable isolator and an insulated housing to prevent incidental shorts during service work. The design relies on a pre-plugged, molded modular assembly that simplifies installation and reduces wiring errors. 

The terminals are rated for up to 20 amps, and the housing is built for high-temperature environments. Color coding supports correct, repeatable connections, and the terminals are made from a highly conductive copper alloy for stable electrical performance.

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Closed-end connectors are crimp-style splicing connectors used to permanently join copper conductors without requiring twist-on installation. They remove guesswork by matching connector size to the correct wire range and crimp profile. The design allows fast, consistent application across all copper wire combinations. They accommodate conductors from 22 AWG through 8 AWG and use a natural nylon housing for insulation and durability.

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TRU-LOCK wire connectors are designed for fast installation on live wires without the mess or difficulty of traditional connectors. They use a nylon skirt with an extra-long extension for added protection and an internal square-wire spring that grips the conductors without binding. The design works with solid or stranded wire combinations and carries a 600-volt maximum rating. The red connectors cover 22–16 AWG, and the blue connectors cover 18–10 AWG.

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The Female Quick Disconnect T-Tap is a self-stripping disconnect terminal designed to make a tap connection without removing insulation. It reduces conductor damage and eliminates time-consuming splicing. It is fully insulated and covers three wire ranges: 22–16 AWG (red), 18–14 AWG (blue), and 12–10 AWG (yellow).

The Bullet Receptacle is a self-stripping terminal used with bullet-style male connectors. It is rated for 14, 16, and 18 AWG conductors and provides a quick-connect joint without manual stripping.

The Insulated Male Snap Plug is a male termination used with compatible snap-style receptacles. It provides a secure, insulated quick-disconnect connection in circuits built with matching plug-and-receptacle components.

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In-line butt connectors are used to join two wires to one wire in a straight-through configuration. They are crimp-style connectors, and the sealed versions include an adhesive-lined tubing that bonds around the conductors after crimping. This adhesive layer provides a waterproof seal around multiple wires and protects the splice from moisture intrusion. A color stripe on the connector identifies the wire gauge range.

Red sealed butt connectors are for 20–18 AWG conductors on both sides.
Blue sealed butt connectors are for 16–14 AWG conductors on both sides.
Yellow sealed butt connectors are for 12–10 AWG conductors on both sides.

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Grounding connectors are used for grounding and bonding non-metallic sheathed cable in general electrical work. They are UL approved and CSA certified and are suitable for equipment grounding, grounding-rod connections, and standard branch-circuit grounding tasks. The design uses a live-action square-wire spring with built-in contoured wings and a heavy-duty thermoplastic shell to provide strong leverage and long-term durability.

These connectors meet the applicable UL, NEC, and CSA requirements and support compliance with several NEC articles. They are suitable for grounding receptacle terminals to boxes under 250-112, for equipment grounding conductors under 250-113, and for splicing or tapping equipment-grounding conductors to boxes under 250-117. 

They apply to lighting fixtures under 370-12, outlet, switch, and junction boxes under 370-17(b), metal boxes under 370-4, and mobile homes and parks under 545-9. They also meet grounding requirements for mobile homes under 550-9 and swimming pools under 680-25.

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Closed-end connectors are used to join two wires into a single circuit when a permanent crimp splice is preferred over wire nuts or end caps. They are crimp-style components engineered to resist corrosion and vibration at the splice point. 

The design includes a sealing tube with an active adhesive that bonds around the conductors after crimping, creating a moisture-resistant, multiple-wire seal that prevents pull-out. These connectors are rated for 600 volts in building wiring and 1000 volts in fixture or sign applications.

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Cool Seal butt connectors create an environmentally sealed splice without the use of heat. They use an anaerobic sealant that cures when the connector is crimped, forming a moisture-resistant barrier as soon as oxygen is excluded. 

This eliminates the need for heat guns, torches, or external heat-shrink tubing and reduces installation errors. The connector body uses nylon for strong insulation and puncture resistance, and the terminal is made from 99.9% copper to maintain high electrical conductivity.

Red Cool Seal connectors are rated for 22–16 AWG.
Blue Cool Seal connectors are rated for 16–14 AWG.
Yellow Cool Seal connectors are rated for 12–10 AWG.

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Non-insulated high-temperature terminals are built for extreme thermal environments and maintain structural performance at temperatures far above standard terminal limits. They use an alloy-steel base material with a nickel-plated finish for oxidation resistance and surface stability under prolonged heat exposure. 

Their continuous operating range spans 900°F to 1200°F, with a maximum rating of 1200°F. They follow the same dimensional profile as standard non-insulated terminals but use the high-temperature alloy in place of copper or brass. Available wire ranges include 22–18 AWG, 16–14 AWG, and 12–10 AWG.

Non-insulated solderless terminals are general-purpose connectors made from soft-annealed electrolytic copper, providing strong conductivity and good ductility for reliable crimping. They are electro-tin plated to resist corrosion and are available for 22–18 AWG and 16–14 AWG conductors.

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Instant auto-electrical connectors are self-stripping connectors designed to make fast tap, tie-in, and pigtail splices without removing insulation. They use a twist, pull-apart, or squeeze action to form the splice. An internal flip-top mechanism and U-element secure the conductors once closed, and the translucent body allows visual confirmation of wire placement. The connectors provide a dependable seal and are rated for two single strands or one double-strand interconnection.

The SCOTCHLOK moisture-resistant tap connector (Model 804) uses a patented application system that forms a gel-based protective seal around the wire and metal elements. This gel barrier provides strong moisture resistance, including protection against salt water and other corrosive environments. 

It is rated for direct burial and submersible use and operates from –40°C to 95°C (–40°F to 203°F). A locking feature maintains long-term splice security. The accepted wire range is 18 AWG solid or 14 AWG stranded, and the connector is suitable for full-voltage applications as long as exposure temperature does not exceed 95°C.

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Nylon liquid-tight strain relief cord connectors are used on stationary industrial equipment where a durable, sealed cable entry is required. The body is molded from nylon, giving the connector a lightweight structure with strong mechanical stability. The design provides extended strain relief for tools, moving machinery, and similar equipment by supporting the cable at the entry point and preventing pull-out or flex damage.

These connectors carry UL, CSA, and VDE certifications and meet IP68 and IP54/IP55 protection ratings, along with UL 514B, IEC 60079-0, and IEC 60079-7 compliance. They operate from –22°F to 212°F (–30°C to 100°C), with a short-term temperature limit of 275°F (135°C). The material is UV resistant and withstands abrasion, oils, acids, solvents, and salt water, providing long service life in industrial environments.

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Self-stripping electrical pigtail connectors are designed to make two- or three-wire pigtail connections without cutting or stripping the conductors. They accept 22–14 AWG wire and are fully insulated once the cap is driven down. The secondary wire is inserted perpendicular to the main wire, and the internal metal element forms the splice when the cap is pressed into place. They provide a secure, insulated connection and are rated for up to 600 volts.

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Self-fusing silicone tape stretches and bonds to itself, forming a unified mass that seals against moisture, corrosion, shock, and vibration. It requires no heat and can be applied even when the surface is wet. The tape is waterproof and resists ozone, salts, road chemicals, and UV exposure. 

It has a maximum operating temperature of 392°F (200°C) and a dielectric strength greater than 400 volts, making it suitable for protective electrical wraps and emergency insulation repairs.

Marker tape uses a refillable dispenser for quick identification work in the field. It bonds permanently to clean cable sheaths and maintains adhesion when exposed to solvents, oils, and common cleaning agents used in MRO settings. 

The tape is used for circuit identification in control, signal, telephone, cable, automotive, and data wiring. It is supplied in standard widths and multiple lengths for routine installation and maintenance tasks.

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Cold shrink tubing is made from pre-expanded EPDM rubber that installs without external heat. The tubing is factory-expanded onto a removable core, and once the core is pulled out, the material contracts and applies constant radial pressure around the splice or cable. This creates a watertight, UV-stable, and chemically resistant seal suitable for both buried and exposed installations. 

The EPDM rubber maintains performance across a wide temperature range, provides strong abrasion resistance, and offers reliable electrical insulation. Typical uses include sealing primary and secondary electrical splices, excluding moisture on bus bars, and repairing cable jackets on circuits rated up to 1000 volts.

Heavy wall and dual wall heat-shrink tubing meet military specifications MIL-I-23053/4 and MIL-I-23053/15. Both operate down to –40°C and require at least 120°C to activate shrinking. Each has a volume resistivity of (10^{14}) ohm-cm. Heavy wall tubing provides a 2:1 shrink ratio with a tensile strength of 2500 psi. 

Dual wall tubing provides a 3:1 shrink ratio with a tensile strength of 2400 psi and includes an internal sealant that flows during heating to improve moisture and environmental protection. Both types provide a dielectric strength of 500 volts per mil, resist fungus, are non-corrosive, and are flame-retardant.

Medium wall tubing meets MIL-I-23053/5, offering a 2:1 shrink ratio and a tensile strength of 1500 psi. Thin wall tubing also meets MIL-I-23053/5 and provides a reduced cross-section with a 2:1 shrink ratio and a tensile strength of 1200 psi. Both operate continuously down to –55°C. Dielectric strength is 400 volts per mil for medium wall and 500 volts per mil for thin wall.

Sealant-lined tubing is available in flexible and heavy wall versions, both engineered to provide an environmental seal once recovered. The flexible type uses a 3:1 shrink ratio and is resistant to fluids, non-corrosive in service, and fungus-resistant. It is used where electrical insulation and environmental sealing are needed without adding excessive stiffness. 

The heavy wall sealant-lined version combines a thick wall profile with an internal sealant layer that flows during heating, giving both moisture sealing and strong mechanical protection for exposed or vulnerable cable sections.

Tubing dimensions are defined by four measurements: expanded diameter, recovered inner diameter, total length, and color. A 3:1 shrink ratio is represented by tubing that begins at an expanded diameter of 0.750 inches and recovers to 0.250 inches after heating. Heavy wall sealant-lined tubing for large cables typically uses a 2:1 shrink ratio and a thicker wall section to meet mechanical strength requirements while still providing a sealed, insulated protective layer.

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Moisture-proofing multi-wire connectors use adhesive-lined heat-shrink tubing to seal and reinforce electrical connections exposed to harsh environments. When heated, the internal adhesive melts and flows around the splice, bonding to the wire insulation, the connector body, and adjacent jacket materials. 

As the tubing recovers, it applies pressure while the adhesive forms a continuous waterproof barrier that blocks moisture and contaminants. These connectors are used where strong environmental protection is required, particularly in harness repair, outdoor circuits, and complex routing where long-term sealing and strain relief are essential.

Wire harnesses use high-adhesive heat-shrink tubing to protect electrical terminals and prevent environmental damage. The tubing forms a solid barrier against corrosive agents such as chlorides, sodium and magnesium salts, abrasion, vibration, and general contaminants. 

It is typically made from polyolefin, which provides flexibility and strong electrical insulation. The material conforms to MIL-R-46846, MIL-I-23053/4, and MIL-I-23053/15 specifications and uses up to a 4:1 shrink ratio to develop a full environmental seal.

The tubing operates from –55°C to 135°C and requires a minimum of 121°C to begin shrinking. It provides a tensile strength of 1500 psi and a dielectric strength of 400 volts per mil. Additional characteristics include low longitudinal change, non-corrosive behavior, and resistance to common industrial fluids.

Clear View adhesive-lined heat shrink tubing is made from cross-linked polyolefin for high structural strength and durability. The exterior surface includes printed wire-gauge markings to simplify size selection during installation. A hot-melt adhesive lining creates a fully waterproof seal when the tubing is recovered. The product meets MIL-I-23053/4 compliance requirements.

The tubing operates continuously from –55°C to 125°C, and the material is self-extinguishing per flammability testing. Tensile strength is 2400 psi, with low longitudinal change during recovery. Dielectric strength is 750 volts per mil. The shrink ratio is 2.5:1, and the tubing is recommended for insulating copper and solder-type terminals where a transparent, adhesive-lined seal is required.

Semi-rigid multiple-wall heat shrink tubing with sealant is built for strong vibration resistance and dependable strain relief. It is used as a replacement for standard shrink-and-solder terminal seals when a more durable environmental barrier is required. 

The material is formulated for continuous operation in high-temperature environments, and the internal sealant flows during recovery to create a reliable moisture-tight seal. The tubing is chemically resistant and withstands abrasion, oil exposure, and general mechanical abuse common in industrial settings.

Bulk Flexi-Wall thin-wall heat shrink tubing is supplied in dispenser boxes for easy handling in shops and maintenance areas. Each box holds a fifty-foot length of tubing and is designed to reduce waste during cutting and use. The dispenser measures approximately seven inches by seven inches by two inches, providing a compact storage format for bench or service-truck organization.

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Standard cable ties are defined by color, minimum tensile strength, length, and width. Tensile strength ratings range from 18 to 50 pounds. Lengths run from 3.5 inches to 15.5 inches, with widths scaled to match each size. These ties conform to Government Specification MS3367.

Colored cable ties list minimum tensile strengths from 18 to 75 pounds and are available in lengths from 4 inches to 14 inches with corresponding widths. They meet Military Specification MIL-S-23190, Type II, Class 1.

Heavy-duty cable ties are built for higher load requirements, with minimum tensile strengths from 50 pounds up to 120 pounds. Available lengths range from 7 ⅞ inches to 48 inches, making them suitable for securing large bundles, heavy hoses, or structural routing where added holding force is required.

Fluorescent cable ties follow the same general dimensions and tensile ranges as standard cable ties, meeting Government Specification MS3367. Their tensile strengths run from 18 pounds to 50 pounds, with lengths extending up to 15 ½ inches. The fluorescent coloration provides enhanced visibility for identification or safety marking in low-light or high-activity areas.

Metal detectable cable ties are engineered for industries where contamination control is critical, including food, beverage, pharmaceutical, cosmetic production, and related MRO work. The material contains dispersed metal content so the ties can be detected by standard metal detection or X-ray inspection systems. 

They comply with U.S. FDA food-contact material regulations and help reduce the risk of foreign-object contamination that can lead to recalls or liability issues. Available minimum tensile strengths include 40, 50, and 120 pounds, with lengths from 4½ inches to 15⅞ inches.

Releasable cable ties are designed for situations where a harness must be opened and resecured without damaging or discarding the tie. They are available in natural or black, with minimum tensile strengths of 50 pounds. Lengths range from 5¼ inches to 14 inches, making them suitable for construction, service work, and any application requiring repeated adjustments.

Low profile cable ties use a low-snag head design for installations where clearance is limited. The saddle-back profile conforms to the bundle and keeps the tie head from protruding, reducing the chance of catching on adjacent components. They are available with minimum tensile strengths of 18, 30, 50, and 120 pounds, in lengths up to 24 inches.

Mounting cable ties combine bundling and mounting in a single one-piece plastic unit. Each tie is specified by its maximum bundle diameter and a minimum tensile strength rating of 18, 30, or 50 pounds. They are approved to Military Specification MS-3367 and are used when a wire bundle must be secured directly to a panel, frame, or structural surface without additional hardware.

Identification cable ties are used to mark and identify cable bundles during installation. They include a flat write-on area large enough for clear labeling and allow identification and bundling in one step. These ties meet Military Specifications MS-3367-1, MS-3367-2, and MS-3367-4. Minimum tensile strengths are 18, 30, and 50 pounds, with tag size varying by part number.

Dual loop cable ties are designed to secure two separate bundles—such as wires, hoses, or tubing—parallel to each other. They prevent abrasion and chafing between bundles while providing strong mechanical support. They are molded from heat-stabilized material that resists impact, abrasion, and common chemicals. The continuous operating temperature rating is 230°F, allowing use in elevated-temperature environments.

Push-mount cable ties use a push-head design that snaps into a 1/8-inch hole, allowing the tie to mount and bundle in a single step. They are available in natural and black with a minimum tensile strength of 50 pounds. Standard lengths are 5½ inches and 7¾ inches.

Stainless steel ties are used in harsh industrial environments exposed to extreme temperatures, chemicals, salts, or high humidity. The stainless material provides high corrosion resistance and maintains strength from –80°F to 1000°F. They are supplied in natural stainless with a minimum tensile strength of 100 pounds.

Fir tree cable ties use an integrated fir-tree mounting stem that locks into a pre-drilled panel hole, giving high holding strength for both indoor and outdoor installations. They are suitable for heavy-duty applications and maintain flexibility at elevated operating temperatures. Available minimum tensile strengths are 50, 100, and 300 pounds.

Button head cable ties secure a bundle to a chassis using a twist-lock button head that allows the tie to be inserted and removed before final tightening. The design provides parallel entry and exit for clean routing. The ties can be operated clockwise or counterclockwise and are heat-stabilized for strong mechanical performance and impact resistance. The material resists moisture and weathering, and the UV-stable black version is suitable for outdoor exposure. Available minimum tensile strengths are 30 and 50 pounds.

Push-mount cable tie bases are used to anchor cable ties to a panel by snapping into a 1/16-inch hole. The design uses centering ears to align the base during installation and a locking latch to hold it securely in place. The base is molded from Type 66 nylon for strength and stability.

Adhesive-back cable tie bases use an adhesive pad to mount securely to a flat surface, providing an anchor point for a wire bundle. They can also be fastened with screws for a permanent installation. They require a smooth, clean, dry, and oil-free surface and support mounting areas up to 1¾ × 1¾ inches. The base supports cable ties rated for at least 75 pounds of minimum tensile strength.

Screw-mount bases are used for securing cable ties on high-density or large grouped cable bundles. The deep cradle design provides added support and stability, and the bases are molded from Type 66 nylon. They are suitable for use in environments up to 185°F and are available in sizes that support cable ties rated for 50-pound or 75-pound minimum tensile strength.

Cable tie installation tools are offered in three types. A lightweight plastic tool is available for ties rated up to 50 pounds. A full-metal tool is also available for ties up to 50 pounds. A heavy-duty all-metal tool is designed for installing cable ties rated at 120 or 175 pounds.

Velcro cable wraps are used for quick bundling or mounting of cables. They install with a simple loop and feature single-piece construction without requiring back-to-back hook-and-loop material. They allow fast removal, repositioning, and the addition or removal of wires during service.

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Rubber grommets are used to protect copper tubing, linkage rods, brake lines, choke and throttle controls, and electrical wiring where they pass through metal. They reduce wear and noise caused by vibration and are made from material suitable for installation in punched metal panels. Sizes vary by inside diameter, groove width, and compatible panel thickness.

Open and closed nylon grommets are used when cables or tubes are already in place. They use a square snap-in design that locks into the panel hole and allows wires, tubing, or other components to pass through the inner opening. The construction ensures a secure snap-in fit, providing edge protection and preventing abrasion on pre-installed assemblies.

Standard nylon grommets protect wires and harnesses from sharp panel edges and resist pull-out forces up to 35 pounds. They snap into place easily, and their sizing is determined by mounting-hole diameter, panel thickness, and overall height. They are suitable for use in standard electrical knockouts sized to approximately ten percent over the nominal hole diameter.

Universal nylon grommets absorb vibration and cushion or position individual or grouped cables, tubing, hoses, or shafts. They use flexible shutters that adjust automatically to different cable sizes and snap-lock securely into panels up to 1/8 inch thick. The material is rated for continuous operation up to 250°F, providing stability in elevated-temperature environments.

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Woven cotton fabric loom is used to cover under-hood wiring, brake lines, and fluid lines. The material is flexible and impregnated with a metallic-asphalt compound that adds oil resistance and abrasion protection. It also provides thermal shielding for areas near exhaust manifolds and piping. The construction meets the specifications required by major vehicle manufacturers for protective loom applications.

Spiral cut loom is used to bundle and protect wires, cables, or hoses. The spiral design allows quick installation, reuse, and easy access for adding or removing conductors. It is highly flexible and resistant to abrasion, solvents, gasoline, and oil. It is commonly supplied in a convenient display box for shop or service-bay use.

Split convoluted loom protects wires, cables, and tubing from heat, pinching, and abrasion. The split construction makes it easy to install on existing runs, including bent or already secured cables. The material is temperature-rated to 250°F and is recommended for all engine-compartment applications where heat and mechanical protection are required.

Convoluted loop clips are used to route and secure wires, tubes, hoses, and similar components. They are replacement parts for various vehicle models and snap directly over the convoluted loom. Harness ribs grip the clip to keep it locked in place. The clips are made from nylon and are rated for service temperatures up to approximately 250°F.

Loom and cable clips are used on cars, trucks, trailers, and recreational vehicles to secure wiring or small cable runs. They are made from spring steel, providing firm retention and long-term durability in areas subject to vibration.

Steel insulated mounting clips are used to secure hoses, tubing, cables, and similar assemblies. They are made from steel and coated with black vinyl plastisol for chemical resistance, while the underlying zinc plating provides corrosion resistance. These clips are offered in multiple sizes with inside diameters from 1/8 inch to 1½ inches and are designed for mounting with either 1/4-inch or 3/8-inch hardware.

Aluminum tubing and cable mounting clips are built with heavy-duty aluminum construction to provide rigidity and long service life. They are recommended where aging, weathering, or abrasion is a concern. Each clip uses a non-porous neoprene covering to protect the tubing or cable from wear. They are suitable for indoor or outdoor environments and are offered in inside diameters from 1/8 inch to 1½ inches.

Hanger clamps are used to mount brake, fuel, and air-conditioning lines. They are made from zinc-plated steel and use an anti-vibration rubber cushion that reduces wear and prevents line damage. The design wraps around the tubing and mounts with a single 1/4-inch screw or bolt. These clamps are engineered for secure, long-term installation in automotive and equipment applications.

Nylon cable clamps are used for securing wires and cable bundles in general routing and management. They are made from weather-resistant, corrosion-resistant nylon and are available in standard white nylon or heat-stabilized UV-resistant black nylon for outdoor use. Each clamp uses a 1/4-inch mounting hole.

Black adjustable adhesive-backed wire clamps use a thick adhesive tape base to mount securely to clean, smooth surfaces. They are adjustable round clamps made from Type 66 nylon and use polyethylene foam tape for strong adhesion. The ratcheting design allows the clamp to lock around different bundle sizes. They accommodate maximum wire bundle diameters from 1/2 inch up to 1 inch.

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Liquid tight conduit is a non-metallic PVC conduit made from gray polyvinyl chloride and built to meet UL Type B requirements. The smooth interior prevents damage to wire insulation and allows fast feeding of conductors. The material is crush-resistant, flexible, and can be cut to length with a knife. It is suitable for indoor or outdoor installation and operates from –18°C to 75°C. Standard sizes are ½ inch, ¾ inch, and 1 inch, supplied in 50-foot lengths.

The matching nylon fittings are designed for indoor and outdoor service. The conduit is pushed directly into the fitting and secured by tightening the sealing nut, eliminating the need for threading. Each fitting includes an O-ring and steel locking nut. Fittings are available in straight and right-angle styles and are offered for ½-inch and ¾-inch conduit sizes.

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The flexible black PVC tubing is a non-metallic protective cover used over wiring or fiber-optic cable. It is highly flexible, abrasion-resistant, and performs well in high-vibration areas. It can be cut to length with a knife and is recognized under the component program. Standard sizes include 3/8 inch and 1/2 inch.

The matching tubing fittings are made from nylon for indoor and outdoor applications. They are offered in straight-in, right-angle, and snap-in straight-in versions and are intended only for use with flexible non-metallic tubing. Assembly is done by pushing the tubing into the fitting and tightening the lock nut or snap-in screw. The fittings accommodate 3/8-inch and 1/2-inch tubing sizes.

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Expanded mesh sleeving is a durable, abrasion-resistant protective sleeve used to shield lines and hoses from road debris and environmental exposure. It cuts easily with scissors and fits bundle sizes up to 3/8 inch. 

The open-mesh design allows fast installation, reduces labor time, and provides effective bundling and protection for a wide range of applications including fuel lines, engine hoses, air and vacuum hoses, marine cables, hydraulic lines, trailer chains, shafts, and harness assemblies. The material offers high resistance to abrasion and chemicals and operates from –46°C to 125°C. It is manufactured from black polyethylene terephthalate and is recognized under UL component standards.

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Five-foot heat shield sleeve is designed to protect nylon lines positioned near high-temperature components such as mufflers and manifolds. It installs over lines up to 1/2 inch in diameter and is suitable for tight or confined routing areas. The sleeve uses an adhesive-free construction for clean installation with no residue. It provides thermal protection for lines exposed to temperatures up to 260°C.

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Alligator clips are rated for up to 10 amps and are made from cadmium-plated steel. They use a screw-type connection. The standard version is 2 inches long with a 5/16-inch jaw opening. A second version measures 1 11/16 inches with the same jaw opening.

General-purpose clips are rated for up to 20 amps and are also made from cadmium-plated steel. They use a screw connection, measure 2 inches in length, and have a 1/2-inch jaw opening.

Heavy-duty clips are rated for a maximum of 25 amps and are constructed from lead-plated steel. They use a screw connection, measure 2 7/8 inches in length, and have a 3/4-inch jaw opening.

Battery charger clips are rated for 50 amps and measure 3 inches in length with a 1⅛-inch jaw spacing. They are copper-plated and equipped with insulated handles. Each set includes one red and one black clip. Typical uses include low-voltage circuits, trickle chargers, timing lights, and general test instruments.

Insulators are available for both alligator clips and general-purpose clips. They are made from red and black vinyl and supplied in matched pairs.

Test leads are supplied as a pair of 30-inch leads made from 18-gauge wire. They are color-coded red and black and provide a fast way to perform basic electrical checks and identify hidden circuit problems.

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Wiring Devices – Hudson Valley MRO Reference

Heavy-duty and industrial type plugs and connectors are built from rugged thermoplastic polyester elastomer and high-tech thermoplastic polyester for high-stress environments. MRO professionals in Carmel, N.Y. depend on these designs because they meet OSHA requirements 1926.405 and 1910.334 while complying with UL and CSA standards. The construction provides double-insulated reliability and withstands high impact, crushing, corrosion, and temperatures from –20°F to 221°F.

Features include high amperage and voltage capability, color-coded terminal clamping screws, captive assembly screws, a cord-grip system, a keyed body and back plate, an integral power-equipment cable clamp, individual wiring chambers, and a dead-front back-wired design. A weather-resistant field-conversion option allows normally non-weather-resistant units to be adapted for damp or wet locations by inserting a sealing disk into the connector cover, meeting NEMA and CSA requirements. 

Industrial Auto-Grip plugs and connectors use an automatic clamping design and follow the NEMA 5-15 configuration, offered in 10-, 15-, and 20-amp ratings at 125 volts AC for wire sizes up to 16 gauge. Another heavy-duty line uses a three-wire grounding configuration for 10–12 gauge conductors and is rated at 15 amps and 125 volts. Hospital-grade plugs and connectors are presented separately and have a soft gray finish.

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Multiple outlet strips are used in offices, work stations, laboratories, computer equipment setups, store displays, and work benches. They provide six grounding outlets and carry a rating of 15 amperes at 125 volts with a continuous maximum load of 1875 watts. The units use a beige plastic housing, include a six-foot cord, a resettable circuit breaker, and a pilot light indicator, and some versions include an on/off switch that controls all outlets.

The Ground Fault Circuit Interrupter (GFCI) in-line portable device detects current leakage and shuts off power in under one-tenth of a second to reduce electrical shock risk. It is intended for wet industrial and construction environments, meets OSHA requirements, and is weather resistant and UL approved. The unit includes an outlet that allows multiple tools to be used, a five-foot cable, and is rated for 15 amperes at 125 volts AC with a maximum load of 1875 watts.

Surge and noise suppressors provide protection against voltage surges and reduce electromagnetic and radio-frequency interference originating from lightning or electrical disturbances. They are housed in beige plastic and intended for office, workshop, and shop environments. 

The unit provides protected output on three full line circuits, has a 5400-joule rating, a 400-volt clamping response, an on/off switch, and built-in noise reduction. Electrical specifications include 15 amperes, 120 volts at 50–60 hertz, and a clamping response time of under one nanosecond.

A heavy-duty metal-housing surge suppressor is also described, accompanied by a disclaimer stating that surge suppressors provide only single-line protection on the AC feed. They do not protect against direct lightning strikes, and the neutral and ground lines remain unprotected.

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Battery – Hudson Valley MRO Reference

Battery terminal protectors are used to prevent corrosion and extend the service life of batteries, terminals, and hold-downs. They install without special tools and are formulated not to dry out, crack, or evaporate. 

The protection reduces loss of cranking power, charge loss from electrical leakage, higher water use caused by overcharging, and increased fuel consumption associated with the extra energy required for overcharging. Versions are available for both top-post and side-post batteries.

Brush-on battery corrosion preventative is a thick, jelly-like red compound used on battery terminals, cables, hold-downs, and trays. It is formulated so it will not drip or sag during application.

Aerosol battery cleaner and protector is a three-way formulation that sprays on, foams to penetrate dirt and corrosion, and then leaves a long-lasting neutral protective coating after cleaning and wiping. The spray is red in color.

Conductive copper compound is a copper-colloidal surface treatment used to lubricate, protect, and improve electrical conductivity at battery posts, connectors, light-bulb bases, lamp sockets, lens gaskets, fuse clips, ground points, electrical contacts, and starter–alternator studs. It minimizes corrosion, prevents green buildup, and allows terminals to be installed and removed without galling or damage. 

The compound improves and maintains electrical connections while blocking water, corrosive fluids, and gases from entering the joint. Its operating temperature range is –50°F to 250°F at the applied surface, and the material remains intact for a short period even when exposed to fire.

Post-style battery cables are intended for cars, light trucks, and marine applications. In New City, N.Y., automotive mechanics count on this style of cable because the forty-nine strands of heavy-duty copper wire and the black PVC insulation hold up against oil, grease, moisture, and temperature extremes.

Available sizes are 2 AWG and 6 AWG. The 2 AWG cables are supplied in positive lengths of 12, 20, and 27 inches and negative lengths of 32, 38, and 43 inches. The 6 AWG cables are supplied in positive lengths of 10, 12, 20, and 24 inches and negative lengths of 26, 28, 30, and 56 inches.

Post style battery cables with regulator wire use a 6-gauge lead-alloy terminal and 6-gauge wire with black PVC insulation and are supplied in lengths from 16 to 32 inches. 

Side terminal battery cables use a lead-alloy terminal with a molded-in steel insert, are fully sealed for non-slip control, and are available in 6-gauge wire with or without a regulator wire in lengths from 24 to 44 inches. 

Post style cross-over cables use a pressure-cast terminal construction that bonds the cable wire and terminal into a solid mass for a reliable electrical joint. 

The right-angle post terminal is used in dual-battery systems operating in series or parallel, and lengths are 112, 126, and 146 inches with a 10½-inch center-to-center terminal spacing.

 Switch-to-starter cables use a corrosion-resistant plated lug and 6-gauge wire with black PVC insulation in lengths of 32, 40, and 48 inches. 

Golf cart cables use 6-gauge wire with black PVC insulation and plated corrosion-resistant lug terminals and are available in post or lug styles in lengths up to 20 inches.

Battery cable is specified as a stranded copper conductor with a thick, easy-to-strip jacket that resists oil, grease, gasoline, alcohol, and acids. The outside diameter is 0.133 inches for 10-gauge cable and 0.187 inches for 6-gauge cable. 

The engine ground strap is a 100-percent copper braid used to ground the engine to the chassis and meets various OEM standards for General Motors, Ford, and Chrysler. It is ¾ inch wide, up to 12 inches long, rated to 600 volts, and provides a clean, positive ground to prevent electrolytic etching of bearings, rings, gears, and shafts. 

Replacement cables are supplied to address corroded terminals, internal wire corrosion, or undersized battery cables and are available in 2-foot, 2½-foot, and 5-foot lengths with the gauge size specified.

Multiple battery harnesses group two or three standard battery cables and use antimony-lead terminals with a steel reinforcing ring and anti-corrosion insulators. The pre-assembled design reduces labor and provides maximum current flow. Harnesses are available in two-battery and three-battery configurations for top-post and stud-type PTO styles, with center-to-center measurements up to 13⅝ inches. 

Vinyl-coated universal post terminals use a red or black vinyl coating that seals the terminal surface, prevents moisture, and provides built-in insulation. They are designed to fit 2-gauge and 4-gauge cables. 

Terminal protector boots are used on post-style battery cables to protect against corrosion, shorts, and exposed positive or negative terminals. They fit 4-gauge and 6-gauge cables and are supplied in red or black vinyl. 

Ground straps for 6-volt or 10-volt systems use a 1-inch-wide copper braid and are provided in 30-inch and 32-inch lengths.

Stud top battery cable uses 6-gauge wire with a molded lead terminal lug and a black PVC jacket and is available in 12-inch and 15-inch lengths. 

Universal post terminals are made from solid lead alloy for a light, strong, corrosion-resistant connection with high conductivity and are supplied in bulk. 

Universal side terminals are also made from solid lead alloy, are intended to repair damaged side-terminal cables, and are sold in bulk.

E-Z Grip terminals use a single set-screw design for quick assembly. They are made from antimony-lead and are compatible with 6-volt or 12-volt batteries. 

Flag post-to-post terminal adapters convert a Group U-1 flag terminal into a post-style connection for use with standard battery cables on utility, garden, golf, and landscape equipment and are used where higher conductivity is required. 

The battery master switch is an adjustable anti-theft and battery-isolation device; a quarter turn of the knob connects or disconnects the battery cable. It is rated for 500 amps cranking and is suitable for marine and fire-service applications.

Optional fuse bypass kit includes a fuse holder, a 20-amp mini fuse, and terminals. It provides an optional fused bypass between the battery post and cable terminal so accessory power remains available when the master switch is disconnected, and the fuse will open before the vehicle fuse in a fault condition. 

Universal lead-free battery terminal is a universal-fit terminal for positive or negative posts and uses a stud-and-nut mount for lug-type cables. It is supplied with 4-gauge or 6-gauge plated copper lugs and is made from lead-free material. 

Top post import car terminals are sized for Asian and European vehicles and use brass or stainless-steel bolt-and-nut hardware with a plastic cover supplied in matching quantities of black and red.

Conversion battery terminals allow side-terminal cables to be connected to top-post batteries without cutting or stripping the cable, providing a straightforward terminal conversion. 

Quick action truck terminals use a fork-lift style opening for fast removal and replacement, are tin-plated for easier soldering, and provide high conductivity; they are sold as a pair. 

The quick action truck terminal adapter raises the terminal height for truck and heavy industrial use and allows post-type battery lugs to be used with a stud-type cable assembly. It can connect up to four cables to a single battery and is made from solid lead with 3/8-inch studs. The adapter is universal for stud-type batteries.

Marine brass terminals are lead-free and provide a quick-disconnect connection for marine use. They provide a corrosion-proof post-to-cable contact surface, meet Coast Guard regulations, and are supplied with all required fasteners. 

Marine terminals made of solid lead also provide a quick-disconnect method for fast battery removal and replacement and include positive and negative markers. 

Military terminals are made of solid lead with a four-way clamp for added strength and allow multiple cables to be connected; they comply with MIL-SPEC-NO. 750 and MIL-SPEC-NO. 750-2. 

Three-way fleet terminals use solid-lead construction with three 4-gauge cable positions and are supplied as a positive-and-negative pair.

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Heavy duty copper battery terminals are made from 131-contact copper for high conductivity. They use raised stamped characters for clear identification and have a bright tin-plated finish for corrosion resistance. 

Configurations include right elbows, left elbows, straights, and flags. Each configuration is defined by cable gauge and polarity, with assigned color codes and die codes for identification and tooling. 

Cable sizes include 1, 1/0, 2/0, 3/0, and 4/0 gauge, and the straight and flag styles also include a universal gray option. Color coding corresponds to size and polarity, with examples such as black or orange designating certain negative terminals. 

Terminal lugs are heavy-duty components marked with tool-and-die color codes and are offered in stud sizes of 1/4 inch, 5/16 inch, 3/8 inch, and 1/2 inch. They accommodate cable sizes from 8 gauge down to 4/0 gauge.

Butt connectors are solid copper splicing components sized for wire gauges from 6 AWG up to 4/0 AWG. Connector length and conductor size determine the correct selection for a given splice.

The Compact Crimp-Master Universal Crimping Tool applies a triangular compression crimp that centers the cable and distributes pressure evenly. It handles wire sizes from 8 AWG through 1/0 AWG. 

The tool provides fifty adjustable crimp settings changed with a two-finger mechanism and produces a true compression crimp rather than an indent. No dies are required, eliminating alignment issues. The tool measures 15-1/4 inches in length and uses a patented head design. It is domestically manufactured.

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Stud Top Battery Terminals use lead-plated construction for conductivity and corrosion resistance. The black PVC insulation allows installation in battery boxes and confined spaces. The positive terminal uses a slit end and the negative terminal uses a closed end. Each terminal uses a crimp-style connection and is supplied with color-coded lead seals to assist with identification during installation.

Stud Top Terminal Kits incorporate a non-rotation design that helps limit corrosion and movement at the connection point. Each terminal uses a vertical three-eighths-inch stud hole and meets dimensional requirements for stud-top applications. The kits include a five-sixteenths-inch wick felt strip and heat-shrink tubing with sealant for moisture protection.

Compression Terminals are copper-alloy components with a tin-plated finish for corrosion resistance. They install with common hand tools and do not require heating. The design provides high current transfer and maintains reliable connection integrity. These terminals are suited for field repair and general heavy-duty service work and require a crimping tool for installation.

Compression Post Style Battery Terminals are supplied in straight and elbow patterns for right- or left-side applications. They are designed for cable sizes ranging from 1/0 gauge up to 4 gauge. The compression design allows the cable to be secured without soldering and maintains a mechanically tight connection.

Heavy Duty Topside Mount Terminals are built from pure copper and finished with a tin plate, or supplied in crimped-and-soldered form. They are produced in straight or double configurations and are non-stackable. These terminals fit cable sizes from 2 gauge through 4/0 gauge and are intended for high-current use.

Stud Topside Mount Stackable Lugs are pure copper components with a tin-plated finish or crimped-and-soldered construction. They are offered only in a lug style and use a smooth terminal face that allows mounting in any orientation. They accommodate 4 gauge through 1/0 gauge cable and use a three-eighths-inch stud mount and lug-tab terminal layout.

Heavy Duty Stud Top Anti-Rotational Stackable Terminals are made from pure copper with a tin plate or crimped-and-soldered construction. They are non-stackable components offered in straight or double configurations. An anti-rotational indent grips the battery post to reduce movement under load. These terminals fit cable sizes from 2 gauge through 4/0 gauge and can be used on either polarity.

Stud Top Battery Nuts are formed from a synthetic, non-conductive material that is engineered for strength while keeping overall weight low. The material formulation provides durability without contributing to electrical conduction.

Un-Plated Seamless Copper Starter Lugs use tin-plated copper to maintain high electrical conductivity and stable current flow. The copper pad is stamped with the wire size for easy identification during installation. The stepped wire barrel increases surface contact with the conductor, improving mechanical grip and pull-out resistance. 

A flared barrel opening is incorporated to simplify wire insertion. These lugs are intended for high-current starter and grounding circuits where reliable transfer and mechanical stability are required.

Professional-grade solderbond terminals and lug systems are built for sealed, soldered battery-cable connections where a moisture-proof and corrosion-resistant joint is required. Each terminal contains a premounted, pre-tinned solder slug sized to establish the correct electrical interface once heated. The shanks are color-coded to match standard terminal identification systems, helping ensure that the correct gauge is used.

The product range covers both small-vehicle and large-vehicle cable sizes, and fleet service is supported through sets designed for up to twenty cable assemblies. Installation follows a defined process: the cable insulation is stripped to the proper depth, heat-activated flux is flowed into the conductor and terminal barrel, controlled heat is applied until the solder fully melts and wets the joint, and heat-shrink tubing is then positioned over the connection to create a sealed, long-term barrier. The result is a solid mechanical and electrical bond built for demanding environments.

Battery-cable terminations of this type are made by fusing a pre-measured metal slug to a stripped conductor, creating a sealed, soldered joint sized to the required cable gauge. The bonding alloy is heat-activated, and the system relies on heavy-wall heat-shrink tubing to complete the environmental seal. The method produces a repeatable, OEM-style termination without the need for specialized tools and is used where a controlled electrical and mechanical connection is required.

Short lengths of heat-shrink tubing are supplied for final protection. After the slug is fully fused to the conductor and the joint has cooled, the tubing is positioned over the termination and shrunk to lock out moisture and reinforce the mechanical structure. The installation sequence consists of inserting the stripped cable into the slug, heating until the bonding alloy flows evenly, allowing the assembly to cool, and finishing the joint by shrinking the protective tubing into place.

Battery bolts are supplied in standard and shoulder-nut styles for securing post-type terminals. The shoulder-nut design improves handling during installation, reduces thread galling, and helps prevent slippage when the fastener is tightened. Variants include long-reach bolts for dual-battery layouts, oversized hex-head bolts for better tool engagement, and extended side-terminal bolts that provide a mounting point for auxiliary connections.

Side-terminal charging posts convert a side-terminal battery into a dual-post arrangement by adding both a positive and negative top-style post. This configuration is used when clamp-type chargers or auxiliary power leads must be attached without removing the original side-terminal bolts.

Accessory side-terminal bolts provide a mounting location for low-amp communication or monitoring devices directly on the terminal. Extended-reach accessory bolts are used on vehicles—especially trucks with dual-battery systems—where added spacing or a direct accessory connection point is required.

Battery jumper cable hardware includes small brass-stud assemblies that create a temporary remote connection point for service work. These mounts install on sheet metal surfaces and provide a fixed clamping location for jump-start cables or diagnostic equipment.

A stud-post converter threads onto an existing stud or side-terminal connection and recreates the geometry of a top-post terminal. This allows clamp-type battery cables to be used where only a stud connection is present.

Replacement battery trays are available in two general sizes to match common automotive battery group formats. They are built from heavy-gauge steel with a protective coating and are dimensioned to hold the shorter case lengths used in compact vehicles or the longer, higher-capacity cases used in larger platforms.

Hold-down bolts are supplied in multiple patterns that match the mounting styles used by various vehicle manufacturers. Each style uses a hooked or J-shaped rod that fits into the battery tray or base casting, with a threaded end for tightening the clamp. Differences between patterns include rod diameter, overall length, and hook geometry to suit Chrysler, Ford, GM, truck platforms, and universal fitments.

Adjustable battery hold-down brackets secure batteries across a wide range of case lengths. The brackets expand or contract in small increments and are built from reinforced polymer material similar to molded battery cases. This construction avoids corrosion and prevents electrical conductivity. Multiple height profiles are available to fit flush-top batteries or designs with raised caps.

A molded mounting block is used on vehicles that rely on a single anchor point to retain the battery. It installs with two screws and stabilizes the side of the battery to prevent movement. This style is common on older passenger cars and light trucks that use a side-mounted clamp system.

A combined base clamp is used on batteries with a Ford-style bottom flange. The clamp fits into the recess along the lower edge of the case and anchors the battery to the tray as the retaining bolt is tightened. It matches the base layouts found on many mid-sized and large battery formats.

A multi-position clamp secures batteries built with a GM-style side or end flange. It can be mounted at either location depending on the tray design or engine-bay layout, giving flexibility where the factory mounting point is offset.

A dedicated base mount is supplied for batteries that use the molded GM bottom geometry. It locks into the tray beneath the battery and provides a single, fixed point for the hold-down bolt.

A universal crossbar is available to replace several older passenger-car crossbar designs. It spans the top of the battery and applies even downward pressure on both sides when tightened, preventing any shifting under vibration. It fits multiple common group sizes and is not restricted by case height.