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I said I would put together a post showing how I do my large cable crimps. The pics below are of a high flex 1/0 battery cable to a 1/0 3/8" hole lug. See attached pics.
- Pic 1: all the materials I used
- Pic 2: Measure and mark how far back the cable jacket will be cut using the lug as a guide.
- Pic 3: Cut the jacket and slide up just enough to apply the first cable tie, apply some lube to the copper (I use spray white lithium grease) and then slide the cable tie over the exposed copper and hand tighten - don't go nuts here.
- Pic 4: slide the jacket up some more and apply 2 more cable ties and lube - make sure you stagger the ratchet heads - DO NOT stack the ratchet heads on top of each other.
- Pic 5: Move the last cable tie up close to the end of the cable copper and then slide the lug over the end and force it onto the cable - the cable tie will slide down as the lug moves onto the cable. If you gat a few copper strands oputside the lug, no big deal, just trim them off at the end of the process before you heat shrink.
- Pic 6: cut the cable tie that's closest to the lug body and continue to force the copper into the lug - repeat for the last cable tie.
- Pic 7: This is what it should look like when the cable has been completely inserted into the lug.
- Pic 8: Crimp the lug with a crimper of your choice. I use a Tepco hydraulic crimper for this, a hydraulic crimper is the right tool when you dealing with big copper and battery connections.
- Pic 9: The finished crimp.
- Pic 10: Completed connection with some nuclear grade Raychem heat shrink. You can find old nuke plant stock on eBay. People are catching on so it's getting expensive and they sell it by the stick now. I bought a ton of this a few years ago for cheap, all different sizes.
Chuck (snook)
- Pic 1: all the materials I used
- Pic 2: Measure and mark how far back the cable jacket will be cut using the lug as a guide.
- Pic 3: Cut the jacket and slide up just enough to apply the first cable tie, apply some lube to the copper (I use spray white lithium grease) and then slide the cable tie over the exposed copper and hand tighten - don't go nuts here.
- Pic 4: slide the jacket up some more and apply 2 more cable ties and lube - make sure you stagger the ratchet heads - DO NOT stack the ratchet heads on top of each other.
- Pic 5: Move the last cable tie up close to the end of the cable copper and then slide the lug over the end and force it onto the cable - the cable tie will slide down as the lug moves onto the cable. If you gat a few copper strands oputside the lug, no big deal, just trim them off at the end of the process before you heat shrink.
- Pic 6: cut the cable tie that's closest to the lug body and continue to force the copper into the lug - repeat for the last cable tie.
- Pic 7: This is what it should look like when the cable has been completely inserted into the lug.
- Pic 8: Crimp the lug with a crimper of your choice. I use a Tepco hydraulic crimper for this, a hydraulic crimper is the right tool when you dealing with big copper and battery connections.
- Pic 9: The finished crimp.
- Pic 10: Completed connection with some nuclear grade Raychem heat shrink. You can find old nuke plant stock on eBay. People are catching on so it's getting expensive and they sell it by the stick now. I bought a ton of this a few years ago for cheap, all different sizes.
Chuck (snook)
