How to: From Binder Clip to Terminal Release Tool

Terminal release tools make wiring the tasks of wiring modifications or alterations feasible. However, in my research the commercially-available release tools are expensive and hard to find. I decided to make my own. I used the methods explained (By Wingnut: http://forums.tdiclub.com/showthread.php?p=672727) in the paperclip release tool method, but in my experience the paperclip didn’t offer enough structural rigidity to free stuck terminals. I went in search of an alternative almost as plentiful as the paperclip.

Materials needed:
1- Binder clip, small size

Tools Needed:
1- Pair of needle-nose pliers
1- Bench grinder, or alternatively, a file
1- Hammer

A piece of wiring containing the terminals inserted into a wiring connector helps during the fine-tuning process, to know when your terminal release tool is working (see below).

http://pics.tdiclub.com/showphoto.php?photo=89693&title=dscf16751&cat=500

Finally, I settled on the binder clip as having the necessary strength of steel to handle the task. I went ahead and removed the tabs from the clip by compressing the spring force holding them into the clip.

http://pics.tdiclub.com/showphoto.php?photo=89694&title=dscf1676&cat=500

Once I had the tabs free from the clip, I began to form them into the shapes necessary to remove both the “micro” (found in CD changer connections) and the “junior” (found in headlight switch connections) sized terminals present in my Mark IV. Two binder-clip tabs = two sizes of terminal release tool.

http://pics.tdiclub.com/showphoto.php?photo=89695&title=dscf1677&cat=500

http://pics.tdiclub.com/showphoto.php?photo=89696&title=dscf1678&cat=500

Here, I have taken a pair of needle-nose pliers and bent the end of the metal tab straight, then to a slight angle to the inside, so that the ends of the clip point towards each other slightly. From here, it is a good idea to bend the clip apart in order to be ground on the bench grinder. This may not be necessary with the file method.

http://pics.tdiclub.com/showphoto.php?photo=89697&title=dscf16801&cat=500

Begin grinding or filing on the first clip until it gains the shape of the “junior” size release tool, which is the larger of the two shown. Here is a photo of the tools I have made in the past. I took most of the material off of the inside of the clip, then proceeded to taper the sides and outside, if necessary. A hammer can come in handy to flatten the end of the clip to obtain the desired shape. Try not to decrease the total length of the clip in this process, a longer tool helps when reaching deep terminals. See photos of completed tools below.

Once a suitable tool has been created, use a wiring connector to test the shape of the prongs. Remove the purple or black locking tab from the connector, and insert the tool with the prongs surrounding the terminal’s top and bottom. It helps to know the shape of a removed connector when first attempting this, but it is not necessary. If the tool doesn’t work, try to alter the shape slightly until the perfect shape is achieved and the tool works to remove the “junior” size terminals. Another trick is to angle the ends of the prongs inward slightly to better depress the terminal locking tabs.

You now have a tool that will release the larger of the terminals; the “micro” tool is next. This one is smaller and a bit more tedious to get right. With the success of your “junior” tool, this shouldn’t be difficult. The prongs have to be tapered from the sides to a greater degree to fit the smaller connectors used to hold the micro terminals, otherwise it is the same process as was just completed. Be careful not to decrease the length, and use a spare wiring connector to test the tool. Eventually it will work, this is the shape I achieved with my “micro” and “junior” tools.

http://pics.tdiclub.com/showphoto.php?photo=89707&title=dscf1690&cat=500

Congratulations, you now have a set of terminal release tools for about $0.10, a far-cry from the $50+ prices charged for the commercially-available tool. Not to say they aren’t worth the price. Doubtless those are more comfortable and will last longer, but for the home mechanic you can’t beat the price of a home-built solution.

http://pics.tdiclub.com/showphoto.php?photo=89702&title=dscf1685&cat=500

http://pics.tdiclub.com/showphoto.php?photo=89703&title=dscf1686&cat=500

http://pics.tdiclub.com/showphoto.php?photo=89709&title=dscf1692&cat=500

There are websites that detail the use of the tools, just search “terminal release tool”.

Please let me know if there are any questions. Thanks for reading!

I would make the pics larger, but I don't know how to achieve that using the club server. If you do, please let me know. I would appreciate it!

EDIT: Found Solution.

Great write-up. You are correct about the strength of the paperclip. Some are stronger than others. My original paperclip pin release tool was much stronger than recent attempts. I guess I got lucky and the paper clip I chose to use for the original was a high quality one. Being such a small tool it easily gets lost. I have had to make at least a dozen over the years. Mostly because I was at a GTG or didn't have mine with me and paper clips aren't all created equally.

Like you, I have made several recently out of a spring clip. Very strong and rigid. Although, I would recommend using a smaller one so that grinding is not necessary. Not everyone has a bench grinder at their disposal. And trying to use a file on such a small object is difficult. By starting with a small one, simply removing the clip, bending to shape with pliers and forging the tips into a flat shape with a hammer is a much easier thing to do for someone with basic hand tools.

Here is the original post the OP was referring to: http://forums.tdiclub.com/showthread.php?p=672727

Thanks Wingnut! Glad you thought it worthwhile, as I piggybacked off of your previous work. Thought it to be quite detailed, maybe this provides a supplement detailing a varying material. Many thanks for providing so many tremendous guides to the club!

As Wingnut mentioned, the method I didn't discuss involves a hammer, and is well-detailed in his how-to (which I have linked, Wingnut willing). A file may or may not work, but would undoubtedly be difficult to use while holding the small object, especially with the relative hardness of the clip... Possibly not a viable method for all but the most determined amateur electricians.

Changed the pics, hope they are easier to see!

Wingnut said:

Great write-up. You are correct about the strength of the paperclip. Some are stronger than others. My original paperclip pin release tool was much stronger than recent attempts. I guess I got lucky and the paper clip I chose to use for the original was a high quality one. Being such a small tool it easily gets lost. I have had to make at least a dozen over the years. Mostly because I was at a GTG or didn't have mine with me and paper clips aren't all created equally.

Like you, I have made several recently out of a spring clip. Very strong and rigid. Although, I would recommend using a smaller one so that grinding is not necessary. Not everyone has a bench grinder at their disposal. And trying to use a file on such a small object is difficult. By starting with a small one, simply removing the clip, bending to shape with pliers and forging the tips into a flat shape with a hammer is a much easier thing to do for someone with basic hand tools.

Here is the original post the OP was referring to: http://forums.tdiclub.com/showthread.php?p=672727

Click to expand...

Hey Wingnut, do you have any of these connectors on hand for loan/rent/or purchase? I'm doing a lot of de-pinning and repinning in the near future on a track car build and don't want to waste money buying from ECS (especially considering their failure rates). I'm local and happy to pick them up in the very near future. PM or send an email to James12lucy @ gmail.com. Spaces are inserted to avoid spam bots.

Thanks!

I make terminal release tools out of street sweeper brush bristles that I find occasionally in the street in front of the shop. Very hard steel and already flat and thin and narrow.