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Unread 10-29-2015, 10:44 AM   #31
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Default Re: Making my own cables

I soldered mine with Rosen flux,
I did not need to put heat shrink on them to avoid influx of acid corrosion, since they are 100% sealed in Solder

Got everything at Ace Hardware
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Unread 10-29-2015, 11:12 AM   #32
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Default Re: Making my own cables

It is probably a good idea to use the adhesive heat shrink with soldered cables as well since the heating process inevitably creates a separation between the cable jacket and the copper cable strands.

A lot more of the cables used for battery power banks where corrosive gasses are present are "Tinned" as well to slow down the corrosion process.

The adhesive part is critical as regular heat shrink tube does nothing to prevent gasses from flowing in.
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Unread 10-29-2015, 11:17 AM   #33
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Default Re: Making my own cables

I used the tool below but haven't powered it up to test the resistance yet.

It's a handheld ratchet crimper and not the size of some I've seen but is supposed to do the job.

Fortunately for me, we have the tool at work so I just had the expense of the cable, connectors and heat shrink. I too used tinned copper because I felt like it would be less susceptible to oxidation/corrosion than un-tinned copper.
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Unread 10-29-2015, 11:51 AM   #34
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Default Re: Making my own cables

Here's how I do it. I get the solid copper lugs and drill a 1/8" hole in the sealed end. After i strip the cable i flux it and put the cable in the vise sticking straight up. The jaws are on the rubber. I drop the lug on it and use a benzene torch to heat the lug. I feed the solider through the 1/8" hole until it follows out the back side of the lug. I then shrink wrap it while it's still in the vise and it's done.
Works great!
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Unread 10-29-2015, 12:01 PM   #35
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Default Re: Making my own cables

The problem with HEAT SHRINK TUBING is that is completely covers up the point where the corrosion occurs and you can't see if it has any until the cable fails.......

I much prefer to have them open where I can see if there is any corrosion on them........That is why they do not cover the point of contact on the batteries..........So you can see and clean any corrosion that might occur............

Now this is ONLY MY OPINION, you guy's do what ever YOU think is best..........For my self, it will be Rosen Flux, and no heat shrink, so, I can monitor any problems as they arise, and not cover it up and wait for it to fail, then say, I DID NOT SEE THAT COMMING !
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Unread 10-29-2015, 12:04 PM   #36
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Default Re: Making my own cables

If you use the adhesive shrink it will prevent that issue, problem is most people use regular heat shrink which this issue can happen.
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Unread 10-29-2015, 12:28 PM   #37
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Default Re: Making my own cables

Quote:
Originally Posted by Sergio View Post
It is probably a good idea to use the adhesive heat shrink with soldered cables as well since the heating process inevitably creates a separation between the cable jacket and the copper cable strands.

A lot more of the cables used for battery power banks where corrosive gasses are present are "Tinned" as well to slow down the corrosion process.

The adhesive part is critical as regular heat shrink tube does nothing to prevent gasses from flowing in.
I don't think most of the people understand the importance of the adhesive heat shrink tubing.I know I didn't until I read this thread last night and did some reading.I also did a search on quality battery lugs and adhesive heat shrink tubing.Regular heat shrink and cheap battery lugs is just looking for early failure and $$ wasted in my opinion.
Quality battery cables cost a lot to make and more if you have to buy a good crimper but since I only have one cart I don't see a crimper in my future ...
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Unread 10-29-2015, 04:07 PM   #38
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Default Re: Making my own cables

Is the a diagram of what cables to replace and what sizes they should be? What about the cables that have several wires running to them?
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Unread 10-29-2015, 04:58 PM   #39
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Default Re: Making my own cables

Did image attach? It's the crimper I'm using.
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Unread 10-29-2015, 05:24 PM   #40
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Default Re: Making my own cables

That die-less crimping tool should work really well, make sure you get quality solid closed end tinned lugs and not cheap Chinese stuff from eBay.

You may want to check the documentation for the tool in case they have recommended brands, otherwise FTZ, Magna lugs, Andersen, Burndy, Thomas & Betts should all work well.

The heavy walled lugs are pretty nice if You are going to keep the cart for a while (they cost more).

Make sure you slide the adhesive heat shrink tube on the cable before You crimp (I know, duh!).

Use the proper size Lug: Batteries, Controller and Motor are 5/16.

The solenoid should be 5/16, but it may be 3/8 if it is a super duty.

You will need (1) 5/16 ring terminal for 10ga cable for the old "combo crimp" on the controler B-.

You will need (1) 5/16 or 3/8 ring terminal for 10ga cable for the old "combo crimp" on the solenoid.

If the cable does not go through the OBC You will need to make a stud.
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