@wilriker said in Largest wire dimension to fit into Duet's Molex KK crimp pins?:
Do I get your method right that you do two crimping operations on each pair of wings by once crimping them towards their end that will go into the connector and once towards the end going to insulation? If not, how are you doing these two steps (per pair of wings) then?
I do use a PA-20.
I crimp the wings that will grip the bare wire once, fairly gently, in the 2.2 slot, and the same wings again, firmly, in the 1.9 slot. This seems to give the best results on the connectors included with the duet. The insulation wings may get 2.5/2.2 or 2.2/1.9, depending on the insulation. Four operations total.
For "radio control" connectors, which are smaller, the final crimp of the wire wings occurs in the 1.6 slot.
I understand what you are saying about the "thickness" of a PA20 vs. the "longways" dimension of the wings, and that it is easy to have a little "hanging out" of one side or the other of the crimper. However, if done carefully, the entire longways/thickness happens in each operation. I find that even with magnifying glasses, I can't get this right entirely by eye... a fingernail really sets the final depth alignment.