Abstract: A method of securing terminals to a distributor cap and to the cap formed thereby. A molded thermoplastic distributor cap is provided which has bores formed in the towers of the cap. Die cast zinc terminals having ribs and recesses therebetween are partially inserted into the bores of the cap. With the terminals partially inserted into the cap they are engaged by an electrically heated head member which causes the terminals and cap material to heat up. When the cap material is heated to a flowable state the terminals are pushed into the cap and cap material is moved into the recesses to anchor the terminals in the cap. The terminals are provided with vent slots.

Abstract: Die cast zinc terminals having ribs and recesses therebetween are partially inserted into the cap bores. An electrical heated head member engages and heats the terminals and temporarily converts the cap material into a flowable state to enable full insertion of the terminals into the cap bores. The cap material moves into the terminal recesses to anchor the terminals in the cap. The terminals are provided with vent slots that vent the interior of the cap to an area adjacent a terminal located at the exterior of the cap. The purpose of the vent slots is to relieve any air pressure that may be caused by air being trapped within a connector boot when a female connector and boot are fitted to a terminal.