By bending the wire around the sharp corner
of the terminal, the oxide layer on both wire
and terminal is crushed or sheared, and a clean,
oxide-free metal-to-metal contact is obtained.
A “Regular” bit wraps the bare wire around the terminal.
A “Modified” bit wraps a portion of insulation around
the terminal in addition to the bare wire.This
greatly increases the ability to withstand vibration.
Regular Modified
In. .010 .015 .020 .025 .030 .035 .040 .045 .050 .055 .060 .065 .070 .075 .080 .085 .090 .095 .100
mm 0.25 0.38 0.51 0.64 0.76 0.89 1.02 1.14 1.27 1.40 1.52 1.65 1.78 1.91 2.03 2.16 2.29 2.41 2.54
.010 .014 .018 .022 .027 .032 .036 .041 .046 .051 .056 .061 .066 .071 .076 .081 .086 .091 .096 .101
0.25 0.36 0.46 0.56 0.69 0.81 0.91 1.04 1.17 1.30 1.42 1.55 1.68 1.80 1.93 2.06 2.18 2.31 2.44 2.57
.015 .018 .021 .025 .029 .033 .038 .043 .047 .052 .057 .062 .067 .072 .077 .082 .087 .092 .097 .102
0.38 0.46 0.53 0.64 0.74 0.84 0.97 1.09 1.19 1.32 1.45 1.58 1.70 1.83 1.96 2.08 2.21 2.34 2.46 2.59
.020 .022 .025 .028 .032 .036 .040 .045 .049 .053 .058 .063 .068 .073 .078 .083 .088 .093 .098 .103
0.51 0.56 0.64 0.71 0.81 0.91 1.02 1.14 1.25 1.35 1.47 1.60 1.73 1.85 1.98 2.11 2.24 2.36 2.49 2.62
.025 .027 .029 .032 .035 .039 .043 .047 .050 .056 .060 .065 .069 .074 .079 .084 .089 .094 .099 .104
0.64 0.69 0.74 0.81 0.89 0.99 1.09 1.19 1.27 1.42 1.52 1.65 1.75 1.88 2.01 2.13 2.26 2.39 2.52 2.64
.030 .032 .033 .036 .039 .042 .046 .050 .054 .058 .062 .067 .071 .076 .080 .085 .090 .095 .100 .105
0.76 0.81 0.84 0.91 0.99 1.07 1.17 1.27 1.37 1.47 1.58 1.70 1.80 1.93 2.03 2.16 2.29 2.41 2.54 2.67
.035 .036 .038 .040 .043 .046 .049 .052 .056 .060 .064 .069 .073 .078 .082 .087 .091 .096 .101 .106
0.89 0.91 0.97 1.02 1.09 1.17 1.25 1.32 1.42 1.52 1.63 1.75 1.85 1.98 2.08 2.21 2.31 2.44 2.57 2.69
.040 .041 .043 .045 .047 .050 .052 .056 .060 .064 .068 .072 .076 .080 .084 .089 .092 .097 .102 .107
1.02 1.04 1.09 1.14 1.19 1.27 1.32 1.42 1.52 1.63 1.73 1.83 1.93 2.03 2.13 2.26 2.34 2.46 2.59 2.72
.045 .046 .047 .049 .050 .054 .056 .060 .063 .067 .071 .074 .078 .083 .087 .091 .096 .101 .105 .109
1.14 1.17 1.19 1.25 1.27 1.37 1.42 1.52 1.60 1.70 1.80 1.88 1.98 2.11 2.21 2.31 2.44 2.57 2.67 2.77
.050 .051 .052 .053 .056 .058 .060 .064 .067 .071 .074 .078 .082 .086 .090 .094 .098 .103 .107 .111
1.27 1.30 1.32 1.35 1.42 1.47 1.52 1.63 1.70 1.80 1.88 1.98 2.08 2.18 2.29 2.39 2.49 2.62 2.72 2.82
Example: If “A”=.020”. “B”=.060”. The terminal diagonal is .063" as shown on chart.
Step 1: Bit, Sleeve and
Pre-Stripped Wire
Step 2: Wire Insertion
Step 3: Wire Anchoring
Step 4: Terminal
Insertion
Step 5: Finished
Connection
METAL-TO-METAL CONTACT
TYPES OF WRAP
TERMINAL DIAGONAL CHART
HOW TO MAKE WIRE
WRAPPED CONNECTIONS
Wire Size Min. number Min. strip
AWG Dia. Dia. of turns force
inches mm (Bare Wire) lbs. gms
16 .051 1.30 4 15 6800
18 .0403 1.00 4 15 6800
20 .032 0.80 5 8 3600
22 .0253 0.65 5 8 3600
24 .0201 0.50 6 7 3200
26 .0159 0.40 7 6 2700
28 .0126 0.32 7 5 2200
30 .0100 0.25 7 3.3 1500
*Conforms to MIL-STD-1130B
STRIP FORCE CHART*
SOME HINTS ON MAKING WRAPPED CONNECTIONS
OPEN WRAP & SPIRAL WRAP
Just keep the OK tool on the
terminal until the wrap is
complete. Early removal can
result in spiral and open wraps.
PIGTAIL
Wire wrapping is a precision technique
and the wrong bit and sleeve just
cannot do the job. Improper selection
can cause problems ranging from
“Pigtails” to loose wraps.
Wire Wrapping is a method of making a wire connection by coiling the bare wire around the sharp corners of a
terminal under mechanical tension. The technology was developed as an alternative to soldering, which presents
various safety and reliability problems in many applications. A principal advantage of wire wrapping is that it
provides a high-reliability connection that is also easily removed to correct or modify a wiring layout. Wire wrapping
subjects the wire to tremendous tension and compression forces, causing the oxide layer on both wire and terminal
to be crushed or sheared, resulting in a clean, oxide-free metal-to-metal contact. A standard wrap is generally used
for 24 AWG and larger diameter wires; a modified wrap is typically used for 24 AWG and smaller wires, and is used
almost exclusively for 28 to 30 AWG wires. In either case, the wrap style affects only the connection’s mechanical
stability; both styles provide suitable electrical connections.
WIRE WRAPPING OVERVIEW
INSUFFICIENT TURNS
It’s easy to feed wire into the slot in the
OK bit correctly. Be sure the stripped end
of the wire is “pushed-in” all the way.
OVERWRAP
Do not press too hard. Let the OK tools
do the work. Excessive pressure can lead
to overwrapping. Backforce "BF" to
prevent overwrapping is available on
most power tools and is recommended
for use with 26 through 30 AWG wire.
DIMENSION A
DIMENSION B
A
B
4134 Marbledale Road • Tuckahoe, N. Y. 10707 www.okindustries.com