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Another fat wire lug connection

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pwmac(at)sisna.com
Guest

Posted: Wed Apr 30, 2008 6:02 am Post subject: Another fat wire lug connection

Comments solicited

  http://fordfuelinjection.com/?p=59



 The world of car battery connections. The link shows a popular way to deal with soldering the big cables.

 The last pic also shows his alt to batt cable with the fat fuse. Used for high amp alts for the off road guys.



 Paul     [quote][b]

echristley(at)nc.rr.com
Guest

Posted: Wed Apr 30, 2008 8:44 am Post subject: Another fat wire lug connection

paul wilson wrote:

 	  Quote: 	
		   Comments solicited

 <http://fordfuelinjection.com/?p=59>http://fordfuelinjection.com/?p=59



 The world of car battery connections. The link shows a popular way to 

 deal with soldering the big cables.

 The last pic also shows his alt to batt cable with the fat fuse. Used 

 for high amp alts for the off road guys.



 Paul 

Good-gawd!!!
	




The propane torch is WAY oversized for this job.  It's like using a Mack 

truck to race around a picnic table 8*)

Get one of the $8 butane torches.  They're useful for all sorts of 

things other than making fat cables, and you won't set the house on fire 

doing it 8*)

Bob McC

Joined: 09 Jan 2006
Posts: 258
Location: Toronto, ON

Posted: Wed Apr 30, 2008 8:47 pm Post subject: Another fat wire lug connection

Ernest;

  

 While I agree with you totally, you  must admit that the results depicted in the photos appear to be pretty  good.

  

 Bob McC

 DO NOT  ARCHIVE

  

  

 [b]---

_________________
Bob McC
Falco #908
(just starting)

Peter Laurence

Joined: 10 Jan 2006
Posts: 50

Posted: Thu May 01, 2008 4:07 am Post subject: Another fat wire lug connection

Where does one find the solder plugs/

  

 P Laurence

 [quote]   ---

Bret Smith

Joined: 09 Jan 2006
Posts: 178
Location: Mineral Bluff, GA

Posted: Thu May 01, 2008 5:31 am Post subject: Another fat wire lug connection

I just soldered my fat wire connectors using  the "Nuckolls Method" and was surprised how easy it was... Kinda fun actually.  http://www.flightinnovations.com/wiring.html#Installing_Battery_Cable_Connectors

  

 Bret Smith

RV-9A "Canopy"

Blue Ridge,  GA

www.FlightInnovations.com

   [quote][b]

_________________
Bret Smith
RV-9A (Emp)

pwmac(at)sisna.com
Guest

Posted: Thu May 01, 2008 5:39 am Post subject: Another fat wire lug connection

In answer to your Q: I cannot find the pellets here in the CO boondocks and I never bothered to goggle them out. I use a small torch and just feed the solder until the cable seats in the lug.

  An interesting point:   The weld cable I am now able to get, unlike Ryan's, melts at a low temp. My method worked fine when I was able to get the dual insulated welders cable. That stuff would not melt even with the overkill torch. With the local obtained cable I have to get the nearby battery guy to crimp the lugs with his pro crimper. I would prefer the better cable, but the dual insulation makes it slightly stiffer.

 I have bought Ryan's alt and cables for my off road trucks. No problem with his service if you need a 175 or 200 amp alt. These alts are '90s to the present Ford units with the regulator attached to the back of the alt. Here is his link. He does not appear to sell pellet separately.   [url=http://rjminjectiontech.com/?p 2] http://rjminjectiontech.com/?p 2[/url]

 Here is a repeat of the guys diy method. Remember he deals with a lot of guys with no clue on how to deal with electrical stuff.

  http://fordfuelinjection.com/?p=59



 Paul

 =========



 At 06:02 AM 5/1/2008, you wrote:

 [quote]Where does one find the solder plugs/

  

 P Laurence

   ---

echristley(at)nc.rr.com
Guest

Posted: Thu May 01, 2008 9:08 am Post subject: Another fat wire lug connection

Robert McCallum wrote:

 	  Quote: 	
		   Ernest;



 While I agree with you totally, you must admit that the results depicted in the photos appear to be pretty good.

   

Indeed, I must.  But how many charred remnants are on the floor? (Or in 
	


his trash can if he isn't as messy as me.)



We're mostly manufacturing one-offs.  How many battery cables do you 

expect to make in your life?  You -could- do the job with a #6 welding 

torch set to a large oxidizing flame given enough practice (not that 

I've tried it, mind you). Those little butane torches are a godsend in 

many applications.  This being one of those.

nuckolls.bob(at)cox.net
Guest

Posted: Thu May 01, 2008 4:21 pm Post subject: Another fat wire lug connection

At 12:39 AM 5/1/2008 -0400, you wrote:



 	  Quote: 	
		  Ernest;



While I agree with you totally, you must admit that the results depicted 

in the photos appear to be pretty good.



Bob McC

DO NOT ARCHIVE



 > Good-gawd!!!

 >

 > The propane torch is WAY oversized for this job.  It's like using a Mack

 > truck to race around a picnic table 8*)

 > Get one of the $8 butane torches.  They're useful for all sorts of

 > things other than making fat cables, and you won't set the house on fire

 > doing it 8*)


	


    I've done this job with all sizes of torches including the

    standard hardware store variety depicted. Up until a few

    months ago, my all time favorite for this size job was

    the Bernz-O-Matic ST100T



http://www.aeroelectric.com/Pictures/Tools/Soldering/Gas_Tools/ST100T_Microtorch_small.jpg



    I used to get them a Home Depot and Lowes for about

    $10 each. They seem to have disappeared from the US

    market but they seem to be available in the UK.



    There's a variety of small gas tools depicted on

    my website at:



http://www.aeroelectric.com/Pictures/Tools/Soldering/Gas_Tools/



    Any one of these tools would be very convenient

    sources of heat for putting the terminals on fat-wires.



    Bob . . .

nuckolls.bob(at)cox.net
Guest

Posted: Thu May 01, 2008 4:24 pm Post subject: Another fat wire lug connection

At 08:02 AM 5/1/2008 -0400, you wrote:



 	  Quote: 	
		  Where does one find the solder plugs/


	


   They're a specialty item that's totally

   unnecessary to the task. For closed barrel terminals

   like that shown in the article, pre-tin your

   conductors out in the open. Heat the terminal

   and fill the wire-grip about 1/3 full of solder.

   Then bring the wire strands up to the rear

   of the wire grip . . . warm them along with

   the terminal until the solder softens and then

   slowly immerse the wire into the terminal.



   I prefer the open barrel terminals like those

   shown in:



http://aeroelectric.com/articles/big_term.pdf



   This style terminal lends itself to "copper-

   wedging" so that you can minimize dependency

   on solder to fill the joint. You can also

   apply solder as needed from the proper end

   and avoid overheating the wire's insulation.



   Bob . . .



        ----------------------------------------)

        ( . . .  a long habit of not thinking   )

        ( a thing wrong, gives it a superficial )

        ( appearance of being right . . .       )

        (                                       )

        (                  -Thomas Paine 1776-  )

        ----------------------------------------

grjtucson

Joined: 07 Apr 2008
Posts: 7
Location: Tucson, AZ

Posted: Thu May 01, 2008 7:22 pm Post subject: Re: Another fat wire lug connection

 	  nuckolls.bob(at)cox.net wrote: 	
		  At 12:39 AM 5/1/2008 -0400, you wrote:

    There's a variety of small gas tools depicted on

    my website at:



http://www.aeroelectric.com/Pictures/Tools/Soldering/Gas_Tools/



    Any one of these tools would be very convenient

    sources of heat for putting the terminals on fat-wires.



    Bob . . . 	




I just got one of these:



http://www.aeroelectric.com/Pictures/Tools/Soldering/Gas_Tools/Pencil_Torch_2.jpg



at Ace Hardware for about $12. Kind like a refillable BIC lighter with an attitude.



Worked great to make ground buses, I suspect it'll do a bang-up job on my fat wire terminals.



George

_________________
George Jenson - http://www.georgejenson.com
Tucson, AZ - RV-7 Standard Build
Empennage Completed 1/06
Wings Completed 11/06
Fuselage in Progress

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