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CountryB · 11-08-2020, 09:50 AM

I have some battery cable terminals to replace, and a two battery jumper cables to make.

I usually put the terminal ends on the cable by holding the terminal in vise grips and heating it up with a propane or mapp torch. Then I melt rosin solder in it filling it about half way. Then I stick the bare copper in it and let it cool, and finish off with heat shrink tubing.

I've done several like this and have not had any problems (that I know of) but I guess the risk here is, moving the cable a little before the solder cools fully and ending up with a cold solder joint.

I wondering it would be a "better" job to just cold crimp the terminals. I can get a hydraulic crimper (good for up to 2/0 cable) off Amazon for around $40.

A hand crimper would be easier to get in tight places - but that's not a problem now. I'm working in the battery tray area. I don't do a lot of battery work these days - but I don't mind getting a new tool

if the job will turn out better.

I'm working with the 1/0 battery cable with copper ring terminals.

What do you guys think?
Crimper or Solder?

DennisZ · 11-08-2020, 09:56 AM

Crimp is always better, it gives a much lower resistance value between the lug and the wire. In aircraft, there is no such thing as a soldered lug, only crimp for this very reason.

jacwjames · 11-08-2020, 11:21 AM

No idea so I did a quick internet search (because you can always believe what's on the internet) and I found that Crimped fittings are much better.

What hydraulic crimper did you find for $40, will it do multiple sizes? I may need to redo my battery cables when I change batteries so I might have to get one.

twinboat · 11-08-2020, 11:31 AM

Unless you heat both lug and cable, your going to get a cold solder joint.

Crimp them, but only if you use the right lug for the size cable.

Jyrocharlie · 11-08-2020, 11:33 AM

Why not BOTH? Crimp, then solder.

fcbbob15 · 11-08-2020, 11:33 AM

On the larger cables like 2/0 $ 4/0 I strip the cable just enough the copper fits in the terminal and crimp in a vise using a 3/8 bolt. I put the terminal in the vise and use the bolt to push/crimp the terminal. I then solder it and put heat shrink tubing on it.

CountryB · 11-08-2020, 12:39 PM

Quote:

Originally Posted by jacwjames

No idea so I did a quick internet search (because you can always believe what's on the internet) and I found that Crimped fittings are much better.

What hydraulic crimper did you find for $40, will it do multiple sizes? I may need to redo my battery cables when I change batteries so I might have to get one.

This one. https://www.amazon.com/dp/B06XR8BY65...v_ov_lig_dp_it

However, I also believe in "you get the quality you pay for".

CountryB · 11-08-2020, 12:43 PM

Quote:

Originally Posted by fcbbob15

On the larger cables like 2/0 $ 4/0 I strip the cable just enough the copper fits in the terminal and crimp in a vise using a 3/8 bolt. I put the terminal in the vise and use the bolt to push/crimp the terminal. I then solder it and put heat shrink tubing on it.

I need a method that I can use "in" the battery tray area because I can't (or don't want to) remove the whole cable to take to my workbench. I only have easy access to the last couple of feet of cable.

I worked in a shop that had a crimping tool. I was nice and easy to use - but that level/quality of tool is going for around $200. I don't know if that means it was better than a $40 crimper. But I have bought enough junk (let's say "inexpensive") tools that I should know better by now.

twinboat · 11-08-2020, 12:44 PM

Quote:

Originally Posted by Jyrocharlie

Why not BOTH? Crimp, then solder.

Why, a good crimp works.

CountryB · 11-08-2020, 12:48 PM

Quote:

Originally Posted by Jyrocharlie

Why not BOTH? Crimp, then solder.

Once you insert the cable to the correct depth, the cable insulation is up against (or nearly against) the terminal shoulder, so you can't heat the terminal without melting/burning the insulation.
I think it needs to be one or the other.

CountryB · 11-08-2020, 12:57 PM

Thanks Dennis and Twinboat. I think you have the answer I'm looking for.

What do you think about the $40 crimper I linked to? Good enough?

Or should I pony up the $ and get a more industrial/professional-use crimper - like this:
https://www.tooltopia.com/SG-Tool-Aid-SGT18840

HarryStone · 11-08-2020, 01:11 PM

This is all you need.

BCam · 11-08-2020, 01:15 PM

Here's a Will Prowse (DIY Solar Power) video with a good review of a $28.59 ratcheting crimper (2 - 8 AWG) on Amazon:

https://www.youtube.com/watch?v=u6KQ-NLk7dM

He even cuts the crimp open to evaluate the quality.

Tbrownski · 11-08-2020, 01:21 PM

Just buy a 20 dollar hammer crimper and then heat shrink after. Works perfect. Most of the time I just stick the crimper in a vise and get it as tight as I can. The cheap hydraulic ones will last about 10 minutes.