Part 3. Termination: The Critical Interface

This is where the connection actually happens—and where most failures begin. This chapter focuses on the science of the interface, ensuring every contact is mechanically sound and electrically invisible.

We dive into the specific technologies that make or break a harness:

• Crimping Mechanics: Achieving the perfect "gas-tight" connection where wire and terminal effectively become one cold-welded mass.
• Alternative Methods: When to use soldering or ultrasonic welding for specialized applications.
• Verification: Why visual inspection isn't enough, and how pull testing and cross-section analysis reveal the truth inside the barrel.

If the termination fails, the system fails. We show you how to get it right every time.