Originally Posted by
unterhausen
the horror is ripping the wire out of the crimped connector when you are miles from anywhere. I might be able to Mcgyver a fix after I fix my flat, but it's just as likely that would be highly unreliable. I friend of mine has problems with his, I haven't ever asked him why. Last time I saw his bike, he had the wrong size connectors on it, I assume that was due to a wheel changing mistake. He really needs to upgrade to the connectorless system.
The connector is not a common size. You have to go to a specialty store to buy it. No automobile manufacturer uses this style of connector, and haven't for the last many decades.
You could 3d print a connector like the Shimano that would work the same, probably a good idea
This leads to a significant point - push-on lugs and the SP wire-wrapping idea all depend on the wire being the right diameter, and on some kind of stiffener to keep the wire from vibrating too badly, fatiguing, and breaking eventually. The SON instructions seem to give limits, or at least SON gives you wire that is probably correct, and tells you how to do strain-relief. One of the other unknowns is getting a crimper that actually fits the lug and the wire.