How to Attach Spade 10 AWG Solid Copper

I have the Klein Tools Journeyman Crimping/Cutting Tool (J1005) which is sold at Home Depot. You can also get it online at a bunch of places, including Amazon.

It works very well. Not sure what price range you're looking at but this is around $35.

As for technique, just line the uninsulated crimp up in the center of the spade & give it everything you have. I've done hundreds of crimps & not one failure. I'm guessing you have split style barrels, so gently squeeze with the insulated crimp just enough to hold the wire snug before nailing it down. Of course, put the pointy part of the crimper on the solid portion of the spade. If you need pics, I'm doing a set now & can send them to you.

Ah, I failed to pick up on the word SOLID. As Jea48 accurately describes the connection, it will indeed fail. My instructions were for multiple wires, which are not necessarily stranded.

Anyway, you will need to solder or spot weld. Perhaps a body shop can do this for you?

I've been following this thread & want to say to solder then crimp is not considered prima facie.

Reb, your initial posts seems to convey crimp over the soldered area, which in essence does not allow direct metal to metal contact. Now I'm getting you are referring to two different contact areas-one for crimping & one for soldering? Your pics don't indicate this. At least I don't see what you're talking about.

There are a few ways to test the reliability of a soldered and/or mechanical joint. I don't think cable companies have their connections subject to shear debonding tests. Here the conventional wisdom is what has worked in the past still works.

Then again, the coolness of DIY is for one to experiment & try other methods; however; that does not mean you're right and everybody else is wrong.

It never ceases to amaze me how much information you read on the internet that is outright wrong

Hi Reb,

OK, now I see what you're getting at. That connection looks very solid. The only thing about that style is you can't utilize the curve of the spade for a contact area. I'm sure there are spades w/a large enough pad you could do that & still have the space for full contact.

I don't do shear debonding tests or instability analysis or any other type of testing using electrical or mechanical devices. I would think a digital analysis at the microscopic level would show any fractures that would lead to failure but I believe those methods are used w/PCB's.

I appreciate your offer to send me a sample but I couldn't test any more that you can.