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Old 06-26-2018, 09:04 AM   #15
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Old 06-26-2018, 09:11 AM   #16
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Quote:
Originally Posted by Rusty Kramer View Post
Hey guys. My battery compartment needs work. New Cables are really needed. Lots of corrosion.
Can anyone advise crimping tools recommended that you have used for the large cables. brand/ type etc.

I want to do it well and have good connections. I am sure this big copper wire cable is going to be cheap!

looking for input from you DIY guys that have had good success with this.
Thanks to all.
Rusty
I just added new batteries and used welding cable (2/0)and had the battery shop crimp on the ends after I measured exactly what I needed. Smashing the lugs with a hammer is not a good method and no the cables and the copper lugs are not what I would consider cheap.
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Old 06-26-2018, 10:22 AM   #17
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Many welding supply stores can make the cables you need and they will have the larger cable sizes needed.
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Old 06-26-2018, 07:11 PM   #18
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I always use welding cable (depending on application anything between 4 AWG and 2/0. I can crimp (I have a crimper) but if I'm making new cables I will solder after crimping. I use shrink tube at each terminal, red for plus and black for negative. For the 6 volt bridging jumpers, I use red cable, and red shrink on one end, black shrink on the other. (Red cable because it is always above ground, and red for the red terminal, black for the corresponding negative terminal.

If anyone want photos I just redid my Ambassador's cabling when I did my annual battery removal and service.
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Old 06-26-2018, 09:05 PM   #19
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Here's a list of stuff I bought from weldingsupply.com to give you and idea of what you'll need and part numbers. Obviously you may not need 12 feet of cable as I was doing a run for an inverter install. The swedge is what is used to crimp the lugs on the cable. You may also want to get heat shrink tubing from a hardware store to put over the lug/cable connection. Not sure why pics keep double posting. Click image for larger version

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Old 06-26-2018, 09:08 PM   #20
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Here's a list of stuff I bought from weldingsupply.com to give you and idea of what you'll need and part numbers. Obviously you may not need 12 feet of cable as I was doing a run for an inverter install. The swedge is what is used to crimp the lugs on the cable. You may also want to get heat shrink tubing from a hardware store to put over the lug/cable connection. Not sure why pics keep double posting. Attachment 208628
Of course the double posted pic went away after editing
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Old 06-26-2018, 11:10 PM   #21
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Quote:
Originally Posted by Rusty Kramer View Post
Hey guys. My battery compartment needs work. New Cables are really needed. Lots of corrosion.
Can anyone advise crimping tools recommended that you have used for the large cables. brand/ type etc.

I want to do it well and have good connections. I am sure this big copper wire cable is going to be cheap!

looking for input from you DIY guys that have had good success with this.
Thanks to all.
Rusty
Rusty,
Setting up new cables for your batteries is not rocket science. We're not talking space shuttle work here. Just some battery cables. Type in Battery cable in a google search and you'll get the proverbial phone book of battery cable. You can buy it in some welding supplies shops and online all day long. And, you can get the cable lugs in same places. And your comment on being "cheap" I hope is tongue in cheek. Battery cable AIN'T cheap. Especially if you get the BIG STUFF, like 4/0 etc. But, depending on the load and or application, you may not need that large.

Now, crimping, that's different animal. When I changed from (3) 12V Interstate Marine RV batteries to (4) Costco Golf Cart 6V units, I made up my own cables. Heck, I didn't even buy the cable lugs. I just had some copper tubing laying around that was the correct size for the new cable I was setting up and, made my own. I cut the tubing, cleaned the inside with a plumbers rotary wire brush and, crimped the end and drilled it for the post size. Then, I broke out my trusty soldering torch and, went to work soldering them.

Care has to be taken not to use too much heat but, enough has to be used for the proper joining of both the cable and the lug. Those cables have now been on there for right at 7 years, ain't broke yet. Crimping is the preferred method. But, to get the correct style and, efficient crimp, a proper tool is needed for the job. Most DIY types won't spend the big dollars for a job that's done maybe once or twice in their life. The Hammer type crimpers will do the job. Are they the best, nope, not at all. But, your vehicle WILL work when done with that type.

In my career with the Fire Dept, I watched many of our mechanics make many, many battery cables. They had a monster sized set of manual crimpers. The handles on them were about 2.5' long. They looked like good sized bolt cutters. But, they did a fine job of crimping all our 2/0 - 4/0 cables and lugs. One thing they always used, each and every time they installed a lug on the end of a cable was some COPPER BASED anti-seize. That did two things. One, it prevented corrosion inside the crimped terminal and, two, it promoted conductivity.

With a little perseverance, you'll get the job done and correctly.
Scott
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Old 06-27-2018, 05:41 AM   #22
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Originally Posted by twinboat View Post
Crimping, with the proper tool is the preferred method.

Smashing with a hammer leaves a questionable crimp.

When soldering, the solder wicks up into the cable making it prone to breaking, rather then flexing.
I've seen the solder melt and the cable fall out.
Yeah....people have been telling me that for the last 25 years and I keep on doing it without ever seeing any failures.
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Old 06-27-2018, 07:18 AM   #23
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I've read that soldered connections could heat up and melt the solder and fall apart - but when I worked in a truck shop (in the 70s-90s) we soldered all the battery terminal ends onto the cables .

That's the way the shop did it (wrong or right) and I never heard of a terminal coming apart. This was on Class 8 trucks.

When I replaced the ends on my MH, I soldered the battery terminal connections. It worked very well and only requires a MAP torch, flux, solder, and heat shrink tubing. Much cheaper than a crimper for 00 - 0000 cable.
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Old 06-27-2018, 09:22 AM   #24
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Quote:
Originally Posted by Rusty Kramer View Post
Hey guys. My battery compartment needs work. New Cables are really needed. Lots of corrosion.
Can anyone advise crimping tools recommended that you have used for the large cables. brand/ type etc.

I want to do it well and have good connections. I am sure this big copper wire cable is going to be cheap!

looking for input from you DIY guys that have had good success with this.
Thanks to all.
Rusty
I added 2 Trojans to some 6 month old Deka Promaster batteries and put in more of the necessary cables. I measured what I needed and had the lugs crimped on and no soldering with the shrink tubing. Big cables and lugs and things work great.
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Old 06-27-2018, 05:25 PM   #25
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re: battery crimping

I purchased a TE-TEMCO crimp on Amazon. It is about $10 and works very well on any cable for your battery system. DO NOT SOLDER ONLY-because if there is a high amp flow the solder can melt. Soldering by itself is not approved. The Temco crimper is simple to use with a heavy hammer. Also, don't use Building Wire such as found at Home Depot. It is not flexible enough or rated for vibration. Use battery cable or welding cable. Windy Nation has good battery cable(Amazon) . And lastly, with DC systems use the shortest length possible and the largest guage wire. I used 4/0 for my 4-6vdc agm batteries (Lifeline) . My system is a 3000 watt inverter, 3- 100 watt solar panels and I can run just about anything. There are some nice YOUtubE videos on crimping battery cables.
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Old 06-27-2018, 07:31 PM   #26
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Here is my setup with cables redone and everything clean!

I removed, cleaned and repaired my cables. Note the use of shrink tube on the terminals of the jumper cables on the house batteries.
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Old 06-27-2018, 10:46 PM   #27
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Well let's see, hmmm, the average solder melts at or around 370 degrees. So, you're saying that, those cables can climb to that kind of temp, without ANY other damage to any other components? Well, I'm certainly no expert but, my soldered battery cables are running year number 7 and, so far, no CHERNOBLE yet!
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Old 09-06-2018, 06:51 AM   #28
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Sorry to come late to this discussion but anyone looking to do DIY electrical stuff will find this Marine How To website useful.
https://marinehowto.com
RC... the owner and author is a marine... ABYC certified electrician and does a great job documenting reviews, evaluations and how to topics.
Topics include a crimper evaluation, how to make your own batty cables and crimping branch circuit wiring.
His evaluation of deep cycle battys is also very enlightening.
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