Battery cable making.....crimping 1/0 terminals?

[alex e]

Guys - For my V8 FJ40 I am making 3 sets of battery cables from 1/0 thick Excelene welding cable with 1/0 copper 3/8 eye terminals secured by 3ply heavy duty adhesive lined, chemical resistant, shrink tubing. Battery terminals are A26 Mil-spec.

For about 30 bucks a set I bought all the materials.

One problem. How do I crimp the terminals? Who knows any secrets for me? Am I doomed to buying a $400 crimper?

Alex

 

[3_puppies]

a good auto electric shop should be able to help you out, they probably could have made them for you to start with

or got any good friends who are commercial electricians? they should have the crimper, it'll only take a few minutes and a case of beer.

 

[blitzkreigfj]

we always drop pellets of solder into the ends, and heat the end, then slide the cable into the end slide your pre -cut shrink tubing over after the end has cooled, heat shrink-done.or use a sledge like my red neck buddy"hasnt failed yet".

 

[DomSmith]

Napa or West Marine should have the manual crimping tool for about $40. Choose the right size, slide on the terminal and whack with a BFH! Very easy to use and I've made all my battery cables with one.

 

[alex e]

I just picked up a blue Cornwell "hammer activated" model for $20.

I just realized I have a Big Blue monster power hammer at the farm in the knife shop. We have dies too.....

What's the method for dropping the solder in there?

 

[Eshu Elegua]

HI alex,,i guess you can check my sig....https://forum.ih8mud.com/40-55-series-tech/258881-my-new-1976-finally-turn-key-40-a.html

 

[Eshu Elegua]

....in the first page

 

[Trollhole]

Slugs are by far the best way I have found. Though I do use slugs and then a flat punch just for extra. Basically on a slug you put the connector but end facing up on a vise and drop the slug in. The push the cable in while heating the connector. Eventually the slug will melt and the end will go all the way in. I always stop when the solder is just about to come out. That's about as solid of connection you can get.

Slugs are sized by wire gauge

2 o'clock

 

[alex e]

THanks Eshu and Marshall!

 

[bsevans]

Don't they have Battery Plus stores in Dallas? I have had the store here in Tucson crimp my hardware for a very minimal fee (sometimes at no cost). They did not care if I bought the cable or lugs from them.

 

[alex e]

Not that I know of. I am making two extra sets and selling them to a buddy with a 40 and an 80 and that will recover my costs of materials and tools. Plus I get to learn something.

 

[Coolerman]

Welcome to Waytek Wire has the manual crimpers, the hammer activated crimper, and the solder pellets in all sizes. The pellets are color coded for size.

I have the hammer model. It works well but so does the solder. Either way if the end is sealed you're good to go.

 

[alex e]

Cooler- That is the same crimper I just bought from Cornwell. I am going to buy the pellets too. How does the hammer crimper process go?

 

[Coolerman]

Raise the spring loaded anvil, place the terminal as shown in the pic (with the wire inserted of course), smack it with a 3lb mini-sledge once or twice, slide your heat shrink up, shrink it and your done.

For winch applications I will crimp it, then solder just the end enough to seal it and heat shrink it. Since these ends are exposed to driving rain, they should be as water tight as possible. I've seen badly corroded winch terminals smoke when winching due to the heat from the high resistance connection.