How To Terminate AC 90 Wire

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How To Terminate AC 90 Wire Two Ways to Strip Armored Cable (AC90/BX): The Right Way & The Lazy Way

Today, we’re going to show you two different methods for stripping armored cable — the proper way and what some call the lazy electrician’s way. Whether you’re wiring a hot water tank, a furnace, or any device below five feet that requires mechanical protection, this tutorial has you covered.

Let’s break it down step-by-step.

What is Armored Cable?

Armored cable — also known as AC90, BX, or simply armour — is used where mechanical protection is required. Typically, you’ll strip 8 to 10 inches off the end of the cable to make your terminations.

✅ The Proper Way to Strip Armored Cable

This method uses a hacksaw and ensures your wires remain undamaged and safely installed.

Steps:

  1. Identify the Rings
    AC90 has spiral rings wrapping around the cable. You want to cut across the rings — not with them — to get a clean break.
  2. Make the Cut
    Use a hacksaw at about a 22° to 30° angle. Carefully saw just deep enough to break through the metal sheath — not into the conductors underneath. Damaging the wires could cause shorts later.
  3. Twist and Snap
    Once you have a good groove, grab the cable on each side of the cut and twist:
    • One hand clockwise
    • One hand counterclockwise
      The rings will snap open cleanly.
  4. Expose the Conductors
    • Pull the armor off.
    • Peel back the paper coating inside the cable.
    • Insert an anti-short bushing (a.k.a. “any short”) to protect the wires from the sharp armor edge.
  5. Install the Connector
    In Canada, we commonly use an L16 dry connector. Slide it over the armor and tighten it down. Use the locknut to secure it into your box, water heater, furnace, or other device.

And that’s the proper, code-compliant way to do it!

⚠️ The Lazy Electrician’s Method (Not Recommended)

If you’re on site without a hacksaw, some electricians will resort to this faster but riskier method.

Steps:

  1. Bend and Crack the Armor
    Bend the armored cable back and forth until you expose a gap in the coils.
  2. Cut the Coil with Side Cutters
    Use side cutters to clip the armor at one of the ribs.
  3. Peel and Remove
    Once cut, simply peel the armor off the conductors.

The Problem:

While this method is fast, it can cause issues:

  • The armor may bunch up or deform, rubbing against the inner wires.
  • Over time, this can lead to abrasion and short circuits, especially if not straightened or protected properly.

We do not recommend this method unless absolutely necessary, and even then, double-check your bushings and clearances.

Final Tips

  • Always use anti-short bushings.
  • Use connectors rated for armored cable.
  • Follow your local electrical code — safety first!

Thanks for watching!

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