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Battery cables

 
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Rocketman1988



Joined: 21 Jun 2012
Posts: 57

PostPosted: Tue Jul 03, 2018 6:48 pm    Post subject: Battery cables Reply with quote

For those who are making their own battery cables, what is the recommended crimp?

Is the indent crimp preferred of a hex crimp?


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art(at)zemon.name
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PostPosted: Tue Jul 03, 2018 8:01 pm    Post subject: Battery cables Reply with quote

I soldered mine according to the instructions here: http://www.aeroelectric.com/articles/big_term.pdf
Easy and seems like I got physically sound, low resistance connections.
    -- Art Z.

On Tue, Jul 3, 2018 at 10:03 PM Rocketman1988 <Rocketman(at)etczone.com (Rocketman(at)etczone.com)> wrote:

Quote:
--> AeroElectric-List message posted by: "Rocketman1988" <Rocketman(at)etczone.com (Rocketman(at)etczone.com)>

For those who are making their own battery cables, what is the recommended crimp?

--
https://CheerfulCurmudgeon.com/"We do not see the world as it is. We see the world as we are."


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ronburnett(at)charter.net
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PostPosted: Wed Jul 04, 2018 2:25 am    Post subject: Battery cables Reply with quote

Art,I have a Harbor Freight set of hydraulic squeezers that work great for that. It has a big set of fittings for every size.
Ron Burnett
May you have the Lord's blessings today!Sent from my iPad
On Jul 3, 2018, at 11:00 PM, Art Zemon <art(at)zemon.name (art(at)zemon.name)> wrote:
Quote:
I soldered mine according to the instructions here: http://www.aeroelectric.com/articles/big_term.pdf
Easy and seems like I got physically sound, low resistance connections.
-- Art Z.

On Tue, Jul 3, 2018 at 10:03 PM Rocketman1988 <Rocketman(at)etczone.com (Rocketman(at)etczone.com)> wrote:

Quote:
--> AeroElectric-List message posted by: "Rocketman1988" <Rocketman(at)etczone.com (Rocketman(at)etczone.com)>

For those who are making their own battery cables, what is the recommended crimp?

--
https://CheerfulCurmudgeon.com/"We do not see the world as it is. We see the world as we are."






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nuckolls.bob(at)aeroelect
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PostPosted: Wed Jul 04, 2018 7:18 am    Post subject: Battery cables Reply with quote

At 05:24 AM 7/4/2018, you wrote:
Quote:
Art,
I have a Harbor Freight set of hydraulic squeezers that work great for that. It has a big set of fittings for every size.

Ron Burnett

Quote:

Take a proposed 4 or 2 awg terminal with
you when you go crimp-tool shopping at HF.
I purchased one a few years ago where
the numbers stamped on the die-sets had
no practical relationship to reality.
The actual hex-holes were way to small for
the numbers in evidence.

Don't know if that's changed/improved
but it's worth checking.

When the HF hydraulic tool proved
inadequate to the job, I soldered the
terminals on . . .

Works good, lasts a long time . . .



Bob . . .


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Rocketman1988



Joined: 21 Jun 2012
Posts: 57

PostPosted: Wed Jul 04, 2018 7:53 am    Post subject: Re: Battery cables Reply with quote

Bob,

That is exactly why I asked the question.

It seems as if the HF dies are the WIRE size, not the wire+connector. This makes the dies FAR too small. I have had good luck with the HF crimper on 8 and 4 AWG wire by using dies that are two sizes larger, i.e. us the #4 die on #8 wire and a #2 die on #4 wire. The crimps look as they should according to the Temco website. I did a pull test on one of the #4 cables...I clamped it in a vise an hung 270 lb from it with no movement...


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Robert Reed



Joined: 22 Oct 2009
Posts: 266
Location: Dallas/Ft.Worth

PostPosted: Wed Jul 04, 2018 8:30 am    Post subject: Battery cables Reply with quote

Agreed that the HF dies were not as indicated, especially if using welding cables but ignored the indicated numbers and used the die that gave the crimped connection that I needed.

Bob Reed
Sent from my iPhone

On Jul 4, 2018, at 10:17 AM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
At 05:24 AM 7/4/2018, you wrote:
Quote:
Art,
I have a Harbor Freight set of hydraulic squeezers that work great for that. It has a big set of fittings for every size.

Ron Burnett

Quote:

Take a proposed 4 or 2 awg terminal with
you when you go crimp-tool shopping at HF.
I purchased one a few years ago where
the numbers stamped on the die-sets had
no practical relationship to reality.
The actual hex-holes were way to small for
the numbers in evidence.

Don't know if that's changed/improved
but it's worth checking.

When the HF hydraulic tool proved
inadequate to the job, I soldered the
terminals on . . .

Works good, lasts a long time . . .



Bob . . .


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ceengland7(at)gmail.com
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PostPosted: Wed Jul 04, 2018 8:48 am    Post subject: Battery cables Reply with quote

On Wed, Jul 4, 2018 at 10:17 AM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
At 05:24 AM 7/4/2018, you wrote:
Quote:
Art,
I have a Harbor Freight set of hydraulic squeezers that work great for that.  It has a big set of fittings for every size.

Ron Burnett

Quote:

  Take a proposed 4 or 2 awg terminal with
  you when you go crimp-tool shopping at HF.
  I purchased one a few years ago where
  the numbers stamped on the die-sets had
  no practical relationship to reality.
  The actual hex-holes were way to small for
  the numbers in evidence.

  Don't know if that's changed/improved
  but it's worth checking.

  When the HF hydraulic tool proved
  inadequate to the job, I soldered the
  terminals on . . .

  Works good, lasts a long time  . . .



  Bob . . .

I recently bought a similar (might be the same) hydraulic crimper from Jet (not the Jet Tools people; this is just a reseller of far-East stuff).
https://jet.com/product/10-Ton-Hydraulic-Wire-Battery-Cable-Lug-Terminal-Crimper-Crimping-Tool-9-Dies/044de210e0e54490b3104f2933a8c4e9

I'd suggest trying this:
https://www.andersonpower.com/_global-assets/downloads/pdf/conversion.pdf

or do a search for 'metric to AWG conversion table'.
Mine makes not perfect looking, but quite serviceable crimps using this type of conversion for the numbers stamped on the dies.
Charlie 


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JOHN TIPTON



Joined: 17 Sep 2006
Posts: 239
Location: Torquay - England

PostPosted: Wed Jul 04, 2018 9:27 am    Post subject: Battery cables Reply with quote

Not so much as 'no practical relationship to reality' more of 'no practical relationship to AWG', I think the numbers relate to square mm or something like that, there is a conversion guide somewhere, I'm sure it was put on here a couple of years ago
John

Sent from my iPad

----x--O--x----
On 4 Jul 2018, at 5:30 pm, Robert Reed <robertr237(at)att.net (robertr237(at)att.net)> wrote:
Quote:
Agreed that the HF dies were not as indicated, especially if using welding cables but ignored the indicated numbers and used the die that gave the crimped connection that I needed.

Bob Reed
Sent from my iPhone

On Jul 4, 2018, at 10:17 AM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
At 05:24 AM 7/4/2018, you wrote:
Quote:
Art,
I have a Harbor Freight set of hydraulic squeezers that work great for that. It has a big set of fittings for every size.

Ron Burnett

Quote:

Take a proposed 4 or 2 awg terminal with
you when you go crimp-tool shopping at HF.
I purchased one a few years ago where
the numbers stamped on the die-sets had
no practical relationship to reality.
The actual hex-holes were way to small for
the numbers in evidence.

Don't know if that's changed/improved
but it's worth checking.

When the HF hydraulic tool proved
inadequate to the job, I soldered the
terminals on . . .

Works good, lasts a long time . . .



Bob . . .



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Eric M. Jones



Joined: 10 Jan 2006
Posts: 559
Location: Massachusetts

PostPosted: Fri Jul 06, 2018 9:44 am    Post subject: Re: Battery cables Reply with quote

Don't forget the Perihelion Design Copper-Clad Aluminum cables. They save 1/2 the weight of a copper cable.

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Copper Cables.pdf
 Description:
Copper Clad Cables

Download
 Filename:  Copper Cables.pdf
 Filesize:  286.71 KB
 Downloaded:  22 Time(s)


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(508) 764-2072
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PostPosted: Fri Jul 06, 2018 11:03 am    Post subject: Battery cables Reply with quote

At 10:53 AM 7/4/2018, you wrote:
Quote:
--> AeroElectric-List message posted by: "Rocketman1988" <Rocketman(at)etczone.com>

Bob,

That is exactly why I asked the question.

It seems as if the HF dies are the WIRE size, not the wire+connector. This makes the dies FAR too small.

Yup . . . They've not fixed it and they've
had 10 years to do it!

Quote:
I have had good luck with the HF crimper on 8 and 4 AWG wire by using dies that are two sizes larger, i.e. us the #4 die on #8 wire and a #2 die on #4 wire. The crimps look as they should according to the Temco website. I did a pull test on one of the #4 cables...I clamped it in a vise an hung 270 lb from it with no movement...

I've got access to CNC production . . . I've
pondered the notion of offering properly sized
dies for that tool. The hydraulics seem to be
fine . . . only the die designers are suffering
a short between the headphones.


Bob . . .


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ceengland7(at)gmail.com
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PostPosted: Fri Jul 06, 2018 11:48 am    Post subject: Battery cables Reply with quote

On 7/6/2018 2:02 PM, Robert L. Nuckolls, III wrote:

Quote:
At 10:53 AM 7/4/2018, you wrote:
Quote:
--> AeroElectric-List message posted by: "Rocketman1988" <Rocketman(at)etczone.com> (Rocketman(at)etczone.com)

Bob,

That is exactly why I asked the question.

It seems as if the HF dies are the WIRE size, not the wire+connector. This makes the dies FAR too small.

Yup . . . They've not fixed it and they've
had 10 years to do it!

Quote:
I have had good luck with the HF crimper on 8 and 4 AWG wire by using dies that are two sizes larger, i.e. us the #4 die on #8 wire and a #2 die on #4 wire. The crimps look as they should according to the Temco website. I did a pull test on one of the #4 cables...I clamped it in a vise an hung 270 lb from it with no movement...

I've got access to CNC production . . . I've
pondered the notion of offering properly sized
dies for that tool. The hydraulics seem to be
fine . . . only the die designers are suffering
a short between the headphones.


Bob . . .
The dies are stamped for metric wire sizes. I sent a message on 7-4-18 detailing it, with a link to metric>AWG conversions. Perhaps it didn't make it through, but it's in the archives at:
http://www.matronics.com/searching/getmsg_script.cgi?INDEX=143869992?KEYS=battery_cables?LISTNAME=AeroElectric?HITNUMBER=2?SERIAL=12445510791?SHOWBUTTONS=YES

Charlie

Virus-free. www.avast.com [url=#DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2] [/url]


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