How to Connect Coaxial Cable the Right Way: Tools, Techniques, and Troubleshootin

Most people assume connecting a coaxial cable is simple—strip, insert, crimp, done. But in reality, coax termination is one of the most precision-dependent tasks in RF and video engineering. A single crushed dielectric, a braid strand touching the center conductor, or a mismatched connector can cause intermittent failure, high return loss, or total signal dropout. This is why TV installers, RF engineers, OEM assembly lines, and even experienced technicians sometimes struggle with coax connections.

To connect a coaxial cable correctly, you need the right stripping and crimping tools, proper prep lengths, compatible connectors, and the correct termination method—crimp, compression, or solder—depending on the cable type and application. The process must maintain precise impedance, shielding continuity, and mechanical stability.

Behind every stable RF link is a mechanically sound connection. At Sino-Media, we frequently see two types of customers: engineers who arrive with complete drawings and precise specs, and buyers who only send a blurry photo and ask, “Can you help me connect this cable?” This article is for both. Whether you are building a professional SMA-terminated LMR-400 assembly or just trying to connect your TV coax, the following guide explains how to do it correctly.

What Tools Do You Need to Connect a Coaxial Cable?

A proper coax connection requires a cable stripper matched to the cable’s OD, a clean cutter, the correct crimp or compression tool for your connector type, and in some cases a soldering kit or specialty tools for micro-coax, semi-rigid, or LMR cables.

The right tools determine whether your coax termination is mechanically strong and electrically stable. Many problems occur because users rely on generic wire cutters or non-adjustable strippers that damage the dielectric or shielding. Coax cables are layered in a way that requires specific precision: jacket, braid/foil, dielectric, and center conductor. A proper tool must strip each layer to the correct depth without nicking the conductor or tearing the foil. Using the wrong cutting or crimping tool will introduce impedance discontinuities and lead to high VSWR, insertion loss, or intermittent RF failure.

Here is a simplified overview of typical tools used with different coaxial cable families:

Different coax families—RG-series, LMR-series, semi-rigid copper tubes, and tiny micro-coax—each require dedicated tooling. RG6 and RG59 (common in TV installations) typically use compression connectors, while RG174 and RG316 need small-format crimp tools. LMR cables require specialty prep tools due to their bonded foil and foam dielectric. Micro-coax cables, used in cameras, medical probes, and compact electronics, require extremely fine strip lengths—often under 2 mm—and cannot be prepared with standard tools

The center conductor also matters—solid conductors crimp differently from stranded versions. Semi-rigid coax uses a solid copper tube for shielding; therefore, a tube cutter and deburring tool are essential to prevent crushing. Tools must match not only the cable but also connector type. SMA connectors require specific hex crimp sizes; BNC connectors have different ferrules depending on impedance rating. Using the wrong die set leads to loose connections or internal deformation. Soldering tools must use temperature-controlled tips to prevent melting dielectric materials such as PE or foam PE.

Because tool choice so heavily affects connection quality, many OEMs prefer suppliers like Sino-Media to handle termination instead of performing it in-house. However, for those performing DIY or field installations, the right tool kit is the foundation of reliable coax assembly.

Cutting and Stripping Tools for Different Cable ODs

A coax stripper is engineered to remove layers in a single action: jacket, shield, dielectric. Adjustable strippers allow users to match strip lengths for RG6, RG59, RG58, and RG174. For LMR cables, specialty prep tools prevent foil tearing. Micro-coax cables require fine blades and microscope inspection to avoid damaging the tiny dielectric. Standard wire strippers cannot be used—they crush the layers and compromise impedance. A clean-edge cutter ensures a perfect perpendicular cut.

Crimping and Compression Tools for Connector Types

Crimp tools must match connector ferrule sizes exactly (e.g., 0.128", 0.255", etc.). SMA, BNC, N-type, and TNC connectors usually use hex crimp dies, while F-type connectors typically require compression tools to produce waterproof terminations. Compression tools apply 360° pressure for a strong mechanical connection, ideal for outdoor installations. Using universal dies risks deforming connectors or creating weak crimps.

Specialty Tools for Micro-Coax, Semi-Rigid, LMR

Micro-coax (0.81 mm, 1.13 mm, 1.37 mm) requires ultra-fine stripping tools and soldering tweezers. Semi-rigid coax uses tube cutters and mandrels for precise bends. LMR cables require dual-blade prep tools to strip the jacket and foam dielectric without tearing the bonded aluminum foil. These tools ensure impedance stability across GHz frequencies.

How Do You Prepare a Coaxial Cable for Connector Installation?

To prepare coax cable correctly, cut it cleanly, strip the jacket and dielectric to precise lengths, shape the shielding evenly, and ensure the center conductor remains straight and undamaged.

Cable preparation is the most critical and error-prone stage of coax termination. Every connector manufacturer specifies exact prep dimensions—typically expressed in millimeters. These lengths ensure the dielectric aligns properly with the connector shoulder and the center conductor extends into the contact pin without excessive play. Incorrect prep lengths cause changes in impedance, poor signal transfer, and unreliable mechanical retention.

Stripping must be done cleanly; scoring or compressing the dielectric alters the spacing that defines characteristic impedance (50Ω or 75Ω). Even a 0.1 mm deformation can cause reflections at high frequencies. Shielding must be spread uniformly to maintain 360° ground contact. Stray braid strands that touch the center conductor cause shorts. Foil layers must remain intact to maintain EMI protection.

Micro-coax introduces additional challenges—dielectric layers are fragile, and center conductors are extremely thin silver-plated copper. Over-stripping or bending the center conductor results in signal failure during vibration or thermal cycling. LMR cables use bonded foil; tearing it reduces shielding effectiveness. RG6 cables used for TV connections require foam dielectric to remain uniform during stripping.

Proper prep makes connector attachment easy and reliable. Poor prep results in intermittent connection failures that are extremely difficult to troubleshoot later.

Strip Coax Without Damaging the Dielectric

The dielectric must remain round and undamaged. Deep cuts create air gaps or dents that alter impedance. Multi-blade coax strippers lightly score each layer and remove them cleanly. For foam PE dielectrics, gentle pressure is essential to avoid compression. For micro-coax, blades must be calibrated to micrometer precision.

Shape Shielding for 360° Ground Contact

Shielding must be folded back uniformly. Braid must not bunch or become uneven; this compromises ground contact. Foil layers should remain intact; tearing reduces shielding effectiveness. For high-frequency connectors, shielding must fully cover the ferrule area.

Correct Prep Lengths for RG / LMR / Micro-Coax

Typical prep lengths (always verify with the connector datasheet):

Which Coaxial Connectors Are Common and How Do You Attach Them?

Common connectors include SMA, BNC, N-type, F-type, TNC, U.FL, and MMCX. They attach using crimp, compression, or solder methods depending on cable size, impedance, and application.

Connector selection determines device compatibility and electrical performance. SMA and N-type connectors are widely used in RF systems such as antennas, routers, and test equipment. BNC connectors serve laboratory and broadcast applications. F-type connectors dominate the TV market. U.FL and MMCX are used inside compact electronics, connecting micro-coax to PCBs. Choosing the wrong connector leads to impedance mismatch and signal degradation.

The table below summarizes some of the most common coaxial connector types:

Connectors differ in their mechanical attachment methods—crimp connectors require ferrules that compress shielding; solder-type connectors bond the center conductor to a pin; compression connectors are waterproof and used for RG6/RG59 installations. Attaching a connector requires aligning the dielectric with the connector shoulder, inserting the conductor into the pin, ensuring full seating, and securing the ferrule or compression sleeve.

SMA / BNC / F-Type / N-Type / U.FL Differences

SMA (50Ω): RF modules, antennas

BNC (50Ω/75Ω): Lab instruments, broadcast

F-Type (75Ω): TVs, set-top boxes

N-Type (50Ω): Outdoor and high-power RF

U.FL/MMCX: Internal micro-coax for compact electronics

Can You Connect a Coaxial Cable Directly to a TV?

Yes—TVs accept 75Ω F-type connectors. RG6 or RG59 cables are typically used. Other connector types (SMA, BNC, N-type) cannot plug into a TV without adapters.

Crimp / Solder / Clamp Attachment Methods

Crimp: Strong, quick, repeatable (SMA, BNC, TNC)

Compression: Waterproof, used for F-type TV cables

Solder: Needed for micro-coax and certain SMA pins

Clamp: Used in military/industrial environments

How Do You Connect Coaxial Cable Using Crimp, Compression, or Solder Methods?

You connect a coaxial cable by preparing the cable to the correct strip lengths, inserting the conductor and dielectric into the connector body, and securing the shielding and ferrule using a crimp, compression, or solder method. Each method has different mechanical and electrical characteristics and is chosen based on cable type, connector design, and performance requirements.

Coaxial cable termination is fundamentally about achieving three goals:

1. Maintaining impedance continuity,

2. Ensuring full 360° shielding connection, and

3. Creating a mechanically stable termination that will not loosen under vibration or repeated handling.

The choice between crimp, compression, and solder methods depends on the connector style, operating frequency, environmental exposure, and mechanical requirements. Each termination approach affects return loss, shielding integrity, and long-term reliability.

Crimp connectors dominate RF applications where consistency and repeatability are essential. Because the shield and ferrule are compressed evenly around the cable, a properly executed crimp termination maintains stable impedance even under high frequencies (1–18 GHz for SMA, for example). However, crimp performance is only as good as the precision of the die set. A mismatched hex size—too large or too small—creates either loose Ferrules or crushed dielectric, both of which degrade electrical performance.

Compression connectors are primarily used for RG6 and RG59 in video and broadband installations. They provide a waterproof seal and a strong mechanical hold without requiring solder or precise ferrule compression. The connector sleeve compresses uniformly around the cable, creating a fully sealed termination suitable for outdoor use. The limitation is that compression connectors are available for fewer connector families, mostly F-type and some newer BNC models.

Solder termination is typically used where mechanical constraints demand a bonded connection or where the connector design requires soldering the center pin. Micro-coax connectors (U.FL, MMCX, IPEX, etc.) depend on soldering due to tiny component size and the need for precise conductor attachment. Semi-rigid coax (with a copper outer tube) also relies heavily on soldering because the shield cannot be compressed like a flexible braid.

Regardless of the method, proper termination follows the same general steps:

• Confirm strip dimensions from the connector datasheet.

• Ensure the dielectric is not deformed during stripping.

• Verify that braid strands are not touching the center conductor.

• Insert the cable fully into the connector until the dielectric seats against the shoulder.

• Secure the connection using the required method (crimp, compression, or solder).

• Inspect visually for gaps, bent conductors, or incomplete seating.

• Perform continuity or return-loss checks for high-frequency systems.

The main termination methods can be compared as follows:

Proper coax termination can appear simple, but the internal tolerances are tight. Even a visually “good” connector can perform poorly if the dielectric spacing is altered or if shielding lacks 360° compression. For high-frequency or mission-critical applications, termination quality directly impacts system reliability.

Crimp Method

The crimp method uses a ferrule that slides over the shielding and is compressed using a hex crimp tool. The center conductor may also be crimped or soldered into a pin depending on connector design.

Process overview:

1. Strip the cable to the connector’s specified lengths.

2. Flare the braid evenly without bunching.

3. Slide the ferrule onto the cable.

4. Insert the dielectric and conductor into the connector body until fully seated.

5. Crimp the ferrule with a properly sized hex die.

6. Perform a gentle pull test to verify retention.

A correct crimp produces uniform compression with no deformation of the dielectric. Crimping is ideal for SMA, BNC, TNC, N-type, and most RF connectors due to consistent performance and repeatability.

Compression Method

Compression connectors are widely used for RG6 and RG59 installations, especially in TV, broadband, and outdoor applications. They use a plastic or metal sleeve that compresses around the cable when activated by a compression tool.

Process:

1. Strip jacket, shield, and dielectric to specified lengths.

2. Ensure braid is folded back smoothly.

3. Insert the cable into the connector until the dielectric reaches the inner stop.

4. Use a compression tool to collapse the sleeve uniformly.

5. Check for full engagement and seal.

Compression connections are highly resistant to moisture and mechanical stress but are available only for certain connector families (primarily F-type, some BNC, and a few proprietary designs).

Soldering Method

Solder termination is required for micro-coax and certain high-frequency or precision connectors. It provides a secure electrical bond but requires more skill and heat control.

Process:

1. Strip extremely small lengths of jacket and dielectric—often under 2 mm for micro-coax.

2. Tin the center conductor if required.

3. Insert the conductor into the connector pin and apply heat carefully.

4. Avoid overheating, which can melt dielectric materials (especially PE or foam).

5. Assemble the connector housing.

Soldering is the only reliable method for connectors like U.FL, MMCX, IPEX, and many semi-rigid terminations. It ensures stable electrical contact but offers less vibration flexibility than crimped ferrules.

How Do You Connect Two Coaxial Cables Together?

Two coax cables are connected using a coax coupler, also known as a barrel connector. The coupler must match the connector family and impedance (50Ω or 75Ω).

Common barrel types:

• F-type female–female (TV systems)

• BNC female–female (video / test equipment)

• SMA female–female (RF modules and antennas)
  

Important considerations:

• Do not mix 50Ω and 75Ω systems unless performance loss is acceptable.

• Couplers introduce minor insertion loss (~0.1–0.3 dB depending on frequency).

• Poor-quality couplers can degrade shielding or cause reflections.

Connecting cables via a coupler is simple mechanically but must follow the electrical rules of impedance continuity to avoid signal degradation.

What Common Problems Occur When Connecting Coaxial Cable and How Do You Fix Them?

Common issues include weak signal, no signal, intermittent connections, high return loss, shielding gaps, impedance mismatch, and damaged conductors.

Troubleshooting coax connections requires examining both mechanical and electrical factors. Mechanical failures include crushed dielectric, loose crimps, or bent conductors. Electrical failures arise from impedance mismatch, EMI leakage, or reflective losses caused by incorrect termination lengths. Many issues stem from improper stripping, shielding contact, or connector selection. Loose connectors often cause intermittent behavior that seems random but results from poor grounding or insufficient ferrule engagement.

Common coax connection symptoms and possible causes:

Signal Drops After Connecting

Common causes:

• Loose connector

• Damaged shield

• Over-bending

• Wrong connector type

Impedance Mismatch or Shielding Issues

Mixing 50Ω (SMA) with 75Ω (F-type) creates reflections. Shielding gaps introduce noise and signal leakage.

Installation Errors Causing High Return Loss

Poor prep lengths, damaged dielectric, braid contamination, or misaligned connections create impedance instability.

When Do You Need a Custom Coaxial Cable Assembly Instead of DIY?

You need custom coax assemblies when your application requires precise tolerances, specific connector combinations, controlled shielding, environmental protection, or repeatable professional-grade performance.

DIY coax termination works for simple TV or low-frequency applications. However, RF, medical, industrial, and aerospace systems require extremely tight tolerances. Custom assemblies eliminate variability by using calibrated equipment, controlled soldering, connector-specific dies, and 100% electrical/mechanical inspection. Drawings ensure exact connector orientation, pin-out, length, and material specifications. Custom solutions also allow specialty jackets (FEP, LSZH), waterproofing, EMI suppression, or micro-coax routing that cannot be done manually.

Projects That Require Pre-Terminated Assemblies

5G modules, aerospace RF lines, medical probes, automotive radar systems, high-frequency sensors.

How Drawings, Specs, Pin-Outs Improve Accuracy

Drawings eliminate guesswork and ensure every assembly is identical. Sino-Media provides CAD-to-PDF drawings within 30 minutes to 3 days.

Custom Options for Length, Connectors, Materials

Customizations include exact length, connector combinations, shielding grade, jacket material, waterproofing, and EMI features.

Conclusion: Ready for a Reliable Coax Connection?

Connecting coax cable properly requires precision tools, correct prep lengths, compatible connectors, and the right termination method. Whether joining two coax cables or installing SMA connectors for high-frequency applications, each step affects long-term signal stability. If your project demands accuracy, controlled impedance, and professional reliability, Sino-Media can support you with custom coax assemblies, drawings, pin-out planning, and no-MOQ production. Share your requirements anytime—we’re ready to help.