How to Make a BNC Cable Using Crimp Connectors
Summary
BNC cables use coaxial cable with BNC connectors to ensure a strong, reliable link for video and RF signals. Though various attachment methods exist, the two main types are solder-and-clamp and crimp. This guide focuses on the crimp method and offers a clear, step-by-step process for assembling a BNC cable with crimp connectors.
There are two main steps to attach a BNC connector:
1. Crimp the cable’s inner conductor to the connector’s center contact.
2. Slide the connector body over the cable’s outer jacket and securely crimp the sleeve in place.
We will explain these in further detail below.
Alternatively, if you were looking for the procedure for using solder and clamp connectors, please see our other guide:
Benefits of Soldering and Clamping BNC Connectors
Lightweight and Affordable Connectors
Buying a crimping tool lets you save money over time by avoiding repeated labor or assembly costs whenever you need to prepare or repair your own cables.
Easy Installation
Crimping is recommended because soldering can be challenging and take more time when working on-site, especially in tight spaces or under time constraints.
Work Procedure
Below are the instructions for fabricating a crimp-type BNC cable. While steps may differ by product, BNCP-58A-K is used as an example. Cable mounting diagrams for all products are available for download on the website under “View Datasheet” on the product details page.
Cut the Cable
Strip the Cable
Crimp the Center Contact
Crimp the Connector Body
Check Continuity and Insulation Resistance
Cut the Cable
Cut the cable to the required length, keeping in mind the "cut length." This is crucial, as the required cut length may differ based on the reference point for the overall length and the connector's internal dimensions. When the cable length is short or used in measurement applications, precision is especially important.
・If the total length is measured from the tip of the connector, the cut length will be shorter.
・If the total length is measured from the base of the connector, the cut length will be longer.
Trivia: Automated Cable Cutters
While cable cutting is typically done manually with cutters, it can also be automated with a cable cutting machine. At Tyclon, we use the “MultiStrip 9480” by Schleuniger, which enables fast and precise cuts. This machine also automates the subsequent “cable stripping” process.
Strip the Cable
Slide the crimp sleeve onto the cable, then cut the insulator, braid, and outer jacket as shown in the cable preparation diagram.When stripping the cable, follow the dimensions in the installation manual. If using a cutter, you can mark the cut points with a marker.
Trivia: Cable Stripping Tools
Cable stripping is typically done with a cutter or similar tool. On job sites, portable and simple strippers are also prized for their convenience. At Tyclon, we use the Coax Strip 5300 and Coax Strip 5500 from Schleuniger. By registering the strip dimensions, we can consistently cut cables to the same exact size, ensuring quick and precise stripping every time.
Crimp the Center Contact
Attach the center contact to the inner conductor and crimp it using section B of the crimping tool. Avoid gaps between insulators and do not crimp the flange of the center contact.
Crimp height at the measuring point varies by tool:
TA-34: 1.84 mm to 1.97 mm
TA-35: 1.70 mm to 1.74 mm
For TA-35, adjust so that (A + B)/2 meets the specified range.
Trivia: Crimp Height
In connector assembly, crimp height is the diameter of the center contact or sleeve after crimping.
Even with the same tool and dial setting, crimp height can vary due to tool wear or technique differences.
Tyclon's cable prep diagrams do not specify dial values.
Instead, follow the steps below to find the optimal setting for the day’s work.
Crimp the Connector Body
Attach the shell so it fits between the insulator and outer conductor (braid) of the coaxial cable.
When the center contact is fully seated, you will hear a click.
Slide the crimp sleeve over the outer conductor and crimp it using section A of the crimping tool.
The crimp height should be 6.10 to 6.13 mm. Adjust the dial as needed.
Avoid contact between the tool’s frame or screw and the connector.
Trivia: Using a Crimp Jig
Crimping the sleeve onto the connector body requires significant force. At Tyclon, we use a custom jig with the crimping tool to improve both efficiency and accuracy.
Check Continuity and Insulation Resistance
All Tyclon cable assemblies undergo continuity and insulation resistance testing after completion. This process helps detect issues like internal wire breaks or soldering mistakes that can't be seen visually. Only products that pass all in-house inspection criteria are shipped.
BNC Cable Using Crimp Connector FAQs
QIs custom cable assembly available?
QIs custom cable assembly available?
Yes, we can manufacture custom cables according to your specific requirements. Please submit your specifications or needs through the inquiry form.
QDo you offer lead-free connectors?
QDo you offer lead-free connectors?
Yes, we offer lead-free connectors made with GloBrass® (lead-free free-cutting brass) from Mitsubishi Materials. For further details, please visit the Lead Free Connectors page.
QWhat is your product inspection process?
QWhat is your product inspection process?
All finished products undergo rigorous 100% continuity and insulation resistance testing. Only items that meet all in-house inspection criteria are shipped.
QCan you handle large-volume orders?
QCan you handle large-volume orders?
Yes, we can accommodate large-volume orders. Please contact us directly to discuss lead times and specific requirements for your order.
Q Is it possible to request product samples?
Q Is it possible to request product samples?
Sample availability depends on the specific case. To inquire about samples, please contact us via the inquiry form for more details and availability.
QCan you supply BNC connectors for both 50 ohm and 75 ohm systems?
QCan you supply BNC connectors for both 50 ohm and 75 ohm systems?
Yes, we offer BNC connectors in both 50 ohm and 75 ohm versions, suited for a wide range of commercial and broadcast applications.
QCan you assist with selecting the right connector for my cable?
QCan you assist with selecting the right connector for my cable?
Yes, our technical team can help you select the appropriate BNC connector based on your cable type, application, and performance needs.