making a 3/8" female electrical spade connector

[Frank S]

I have not fewer than 5 electrical connector kits and not one of them had the connector I needed.
I finally was going to get around and change the key switch on my Backhoe since the key broke off in it 6 months ago I have been using pliers to turn the switch. Only the new switch has 3/8" blade connectors the old switch had 1 of the large connectors but for the new one I needed a second large connector.
I solved this problem with a piece of .030" brass drop from the shim washers I made a while back
her is how I made the connector I scribed a rough layout on the brass then cut with snips, no concern with getting too critical with size I just needed it to carry current not be pretty for sale.


After the initial forming over a piece of 3/8 HSS I checked for size against the spade on the switch

I then made a forming jig out of a 3/32 welding rod to roll the sides of the connector over this would make the spring type holding clamp of the connector

The shape of the connector after forming over the rod

It will now lock onto the blade the next step will be to form the crimp tube end


the wire now crimped in place

the completed connector attached to the switch with shrink tube insulator