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--></style></head><body lang="EN-US" link="blue" vlink="purple"><div class="WordSection1"><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d">James:</span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d">Sorry I forgot to include the fine option you introduced. Thank you for the reminder.</span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d">William</span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal"><span style="font-family:"Arial","sans-serif";color:#1f497d">Miller Solar</span></p><p class="MsoNormal"><span style="font-family:"Arial","sans-serif";color:#1f497d">17395 Oak Road, Atascadero, CA 93422</span></p><p class="MsoNormal"><span style="font-family:"Arial","sans-serif";color:#1f497d">805-438-5600</span></p><p class="MsoNormal"><span style="font-family:"Arial","sans-serif";color:#1f497d"><a href="http://www.millersolar.com/"><span style="color:blue">www.millersolar.com</span></a></span></p><p class="MsoNormal"><span style="font-family:"Arial","sans-serif";color:#1f497d">CA Lic. 773985</span></p><p class="MsoNormal"><span style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal"><b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif"">From:</span></b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif""> James Jarvis [mailto:<a href="mailto:jj@aprsworld.com">jj@aprsworld.com</a>] <br><b>Sent:</b> Wednesday, September 3, 2025 4:33 PM<br><b>To:</b> <a href="mailto:william@millersolar.com">william@millersolar.com</a>; RE-wrenches<br><b>Subject:</b> Re: [RE-wrenches] Ferrules for large fine-stranded wire.</span></p><p class="MsoNormal"> </p><div><div><p class="MsoNormal">William,</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">None of the crimpers you sent photos of are for ferrules. Those are all lug crimpers. Some are barely that. Nobody should be seriously considering anything you hit with a hammer to be a proper tool for installing any type of connector.</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">Ferrule crimpers produce a square crimp and do what they are supposed to.</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">Last Wednesday I sent you a note with this link:</p></div><div><div><p class="MsoNormal"><a href="https://www.ferrulesdirect.com/collections/hand-crimping-tools/products/vag240" target="_blank">https://www.ferrulesdirect.com/collections/hand-crimping-tools/products/vag240</a></p></div><div><p class="MsoNormal"> </p></div></div><div><p class="MsoNormal">It makes a square shape and won't have weird edges and the artifacts you mention you get when you smoosh a ferrule with a non-ferrule crimper.</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">Ferrules are highly useful and reliable when installed correctly. You just need the right tool.</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">The other thing I mentioned last week were pin adapters. They are crimp on fittings that are rated for fine stranded wire and they convert it to course stranded or solid shape. Here was the example I sent:</p></div><div><p class="MsoNormal"><a href="https://www.ilsco.com/Ilsco/ccrz__ProductDetails?sku=F2C-1%2F0-1%2F0-ILSM-ILS&cclcl=en_US">https://www.ilsco.com/Ilsco/ccrz__ProductDetails?sku=F2C-1%2F0-1%2F0-ILSM-ILS&cclcl=en_US</a></p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal">Best regards,</p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal"> </p></div><div><p class="MsoNormal"> </p></div><div><div><div><div><p class="MsoNormal">-James Jefferson Jarvis<br>APRS World, LLC<br>+1-507-454-2727</p></div><p class="MsoNormal"><a href="http://www.aprsworld.com/" target="_blank">http://www.aprsworld.com/</a></p></div></div></div><p class="MsoNormal"> </p></div><p class="MsoNormal"> </p><div><div><p class="MsoNormal">On Wed, Sep 3, 2025 at 6:10 PM William Miller via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org">re-wrenches@lists.re-wrenches.org</a>> wrote:</p></div><blockquote style="border:none;border-left:solid #cccccc 1.0pt;padding:0in 0in 0in 6.0pt;margin-left:4.8pt;margin-right:0in"><div><div><div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">Friends:</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">My understanding is if the lug has a set-screw that contacts the strands, fine strands can wind around the set screw, get into the threads and not tighten adequately. If you are crimping fine strands inside of some type of barrel your connection should be OK. </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">I had been using Outback until they imploded and all of the battery connections were via studs or bolts that required crimped-on rings. Now I am back to set screw lugs and fine stranding became an issue again.</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">I did try another experiment: I took a 4/0 ferrule that would not fit into the Envy lugs and snipped a section out of it. I curled it into a slightly smaller diameter and it fit into the lug. I suppose one could cut the ferrule in half longitudinally and insert a portion of the ferrule between the set screw and the strands.</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">I am pleased with the copper sheeting wrapped around the fine strands. That will be my SOP.</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d">William</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Arial","sans-serif";color:#1f497d">Miller Solar</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Arial","sans-serif";color:#1f497d">17395 Oak Road, Atascadero, CA 93422</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Arial","sans-serif";color:#1f497d">805-438-5600</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Arial","sans-serif";color:#1f497d"><a href="http://www.millersolar.com/" target="_blank">www.millersolar.com</a></span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Arial","sans-serif";color:#1f497d">CA Lic. 773985</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="color:#1f497d"> </span></p></div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif";color:#1f497d"> </span></p><div><div style="border:none;border-top:solid #b5c4df 1.0pt;padding:3.0pt 0in 0in 0in"><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif"">From:</span></b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif""> RE-wrenches [mailto:<a href="mailto:re-wrenches-bounces@lists.re-wrenches.org" target="_blank">re-wrenches-bounces@lists.re-wrenches.org</a>] <b>On Behalf Of </b>Ray Walters via RE-wrenches<br><b>Sent:</b> Wednesday, September 3, 2025 1:40 PM<br><b>To:</b> <a href="mailto:re-wrenches@lists.re-wrenches.org" target="_blank">re-wrenches@lists.re-wrenches.org</a><br><b>Cc:</b> Ray Walters<br><b>Subject:</b> Re: [RE-wrenches] Ferrules for large fine-stranded wire.</span></p></div></div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"> </p><p>I've got to ask: Are none of the lugs on these Chinese inverters approved for fine strand cable? I just have not had a problem with that, but I've mostly used Magnum, Midnite, and Outback equipment over the years. What were the lugs on the old Trace DC 250 boxes? Were they fine strand rated? They sure were tough to get 4/0 into, as William mentioned. </p><p>Ray <br>Remote Solar</p><div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto">On 9/3/2025 12:57 PM, Kent via RE-wrenches wrote:</p></div><blockquote style="margin-top:5.0pt;margin-bottom:5.0pt"><p>William,</p><p>If the only reason the ferrule wouldn't fit after using the hex crimper was the ridge left where the dies meet, you could rotate the cable 120 degrees and crimp the ferrule again.</p><p>I doubt that the indenter crimper will do a decent job with large ferrules.</p><p>I do like your thin piece of copper solution. Not UL approved but I dare say wrench approved.</p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto">Kent Osterberg<br>Blue Mountain Solar </p><p> </p><div><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto">On 9/2/2025 8:55 PM, William Miller via RE-wrenches wrote:</p></div><blockquote style="margin-top:5.0pt;margin-bottom:5.0pt"><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">Friends:</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">Thank you for all of your input on this question. I feel it only right I report back how this turned out</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">I tried a crimper like this:</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"> </p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">It left a jagged ridge on both sides of the ferrule where the dies met.</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">The crimper below was suggested but I have not tried it:</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"> </p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif"">This was suggested but I have not tried it either:</span></p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"> </p><p class="MsoNormal" style="mso-margin-top-alt:auto;mso-margin-bottom-alt:auto"><span style="font-family:"Verdana","sans-serif""> </span></p></blockquote></blockquote></div></div><p class="MsoNormal" style="margin-bottom:12.0pt">_______________________________________________<br>List sponsored by Redwood Alliance<br><br>Pay optional member dues here: <a href="http://re-wrenches.org" target="_blank">http://re-wrenches.org</a><br><br>List Address: <a href="mailto:RE-wrenches@lists.re-wrenches.org" target="_blank">RE-wrenches@lists.re-wrenches.org</a><br><br>Change listserver email address & settings:<br><a href="http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org" target="_blank">http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org</a><br><br>There are two list archives for searching. 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