The pin will bend at an angle on the other side of the crimper, and the wire will just be severed. Here, what usually goes wrong is the wire gets cut. I move the connector over a bit so the strain relief is in the crimper jaws, and then crimp. I'll usually do this in the bigger slot first, and then crimp again in the smaller slot. Assuming I do actually get the wire to crimp, then I'll try to crimp down the strain relief. Once in a while I can actually get the crimp to hold. One ratchet click less and the pin is loose in the jaws. If I crimp down enough that the pin is secure in the jaws, it's one ratchet too many and I can't slide the wire into the pin since it's already crimping down. I'm basically trying to do a three-handed job - hold the wire, hold the pin steady, and squeeze the crimper handle. Usually, the act of pushing the wire into the pin moves it just enough that it's almost impossible to keep things aligned. This is where things can start to go wrong. It's already really hard to do this accurately. At this point I'm trying to get the bare wire crimped into the connector. I'll very carefully (it's hard to keep everything still) place the wire in the pin so just the insulation is inside the strain relief section, and crimp. Then I'll place the Dupont pin in the crimper's smaller slot, with the strain relief pin sticking out. If it's stranded I'll twist the strands together. I usually strip off around 1/4" of the insulation on the wire. I've tried both solid core and stranded wire. I've tried crimping various gauges of wire from 22 up to 26, with similar issues. Here is the crimper I purchased, along with some Dupont connectors like these. I'm having similar issues with JST, but one thing at a time. I am getting quite frustrated with my inability to reliably build wiring harnesses using simple Dupont connector pins.
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