Wire terminal Insulator questions

Sorry Gerorge. Have to disagree with you on that one.
Those parts stores closed barrel crips are not what I would rely on - especially for a connection that will be carrying high load and may or may not have good cable support.


The original seals are difficult to replicate. They are extra insurance against oxidation at the crimp and making its way up the wire strands.
My suggestion was to fix the old ones. If that was not possible, do an inline splice.
Inline wiring splice clips........from the Dodge RAM service manual

If you must install a new ring terminal then get the best crimpers you can for a heavy gage terminal. You may want to solder for good measure. The original seal might be usable for a reinstal with heat shrink and/or liquid electrical tape.

There must be enough room on the ring terminal for all of the conducting surfaces to have good contact.
There must be enough wire for some strain relief and not too much which would allow the wires to vibrate and move around eventually causing the junctions to fail.

Yes we discussed it but its OK to bring it up again. Pictures of salvaging a heavy ring terminal and insulator here.
Amp Gauge Wire Diameter (AWG)

and what I did when I added a parallel alternator output line along the lines of the heavy duty option.
Rally dash redo