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Rocketman1988
Joined: 21 Jun 2012
Posts: 63
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 Posted: Tue Jul 03, 2018 6:48 pm Post subject: Battery cables |
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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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| Posted: Tue Jul 03, 2018 8:01 pm Post subject: Battery cables |
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I soldered mine according to the instructions here:Â 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?
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--
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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| Posted: Wed Jul 04, 2018 2:25 am Post subject: Battery cables |
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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:
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nuckolls.bob(at)aeroelect
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| Posted: Wed Jul 04, 2018 7:18 am Post subject: Battery cables |
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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
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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: 63
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| Posted: Wed Jul 04, 2018 7:53 am Post subject: Re: Battery cables |
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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: 331
Location: Dallas/Ft.Worth
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| Posted: Wed Jul 04, 2018 8:30 am Post subject: Battery cables |
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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
|
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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| Posted: Wed Jul 04, 2018 8:48 am Post subject: Battery cables |
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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
|
 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.
CharlieÂ
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JOHN TIPTON
Joined: 17 Sep 2006
Posts: 239
Location: Torquay - England
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| Posted: Wed Jul 04, 2018 9:27 am Post subject: Battery cables |
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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
|
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: 565
Location: Massachusetts
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| Posted: Fri Jul 06, 2018 9:44 am Post subject: Re: Battery cables |
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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 |
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_________________
Eric M. Jones
www.PerihelionDesign.com
113 Brentwood Drive
Southbridge, MA 01550
(508) 764-2072
emjones(at)charter.net |
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nuckolls.bob(at)aeroelect
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| Posted: Fri Jul 06, 2018 11:03 am Post subject: Battery cables |
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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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| Posted: Fri Jul 06, 2018 11:48 am Post subject: Battery cables |
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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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