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Unread 03-14-2009, 11:25 PM   #11
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Default Re: soldering battery lugs

[quote=scottyb;160434]
Quote:
Originally Posted by Extractor View Post
yup, that is exactly how I am doing it. Clamped in a vice and all, step by step exactly how I am doing it. I'll check the melting temp of my solder...no idea. 40/60 rosin core.[/QUOTE]

Ditch the resin core! That is the problem!!!!!
My work here is done

OH! Told you... single digit!!
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Unread 03-14-2009, 11:31 PM   #12
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Default Re: soldering battery lugs

I got rosin core from gmorrison in a different thread,
quote: Soldering 101.
Good hot soldering iron - or - propane tourch (is better)
Good solder - resin core - Not Acid
Flux cleaner - a inexpensive can of flux cleaner is best (small can) $2.00
A place to hold parts in place.

There's resin core, rosin core, and acid core?
So, I should use Acid Core I assume! grrrrrrrrrrrrrrr

Last edited by Extractor; 03-14-2009 at 11:40 PM.. Reason: single digit IQ
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Unread 03-14-2009, 11:42 PM   #13
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Default Re: soldering battery lugs

Try this if you keep having trouble...

Example: Have you ever soldered copper pipe before with let's say an elbow and a straight piece of pipe? CLEAN the outside of the pipe and the inside of the elbow, apply lots of flux to both the inside of the elbow and the outside of the pipe, put both pieces together and HEAT BOTH at the same time and once they are BOTH HOT apply the solder to the edge. It will draw into the elbow at a nice shiny silver color then you remove the heat and you're done.

Same principle, both need to be hot at the same time for it to work well and prevent a cold solder joint, the solder will be drawn into the lug and strands of wire.
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Unread 03-15-2009, 12:06 AM   #14
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Default Re: soldering battery lugs

That's true scubba but I find it impossible to preheat the cable end without comprimising the sheath or coating......
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Unread 03-15-2009, 12:24 AM   #15
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Default Re: soldering battery lugs

I hear you Scotty and it's very true but as I stated... when all else fails for Extractor...

As long as Extractor bends the cable at 90 degrees to the lug and the majority of the flame is at the lug itself I believe it would make it much easier for him to finally get a successful soldering weld under his belt. Now if that doesn't work I believe a crimping tool would be in order!
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Unread 03-15-2009, 09:21 AM   #16
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Default Re: soldering battery lugs

Extractor--Stay with this and let us know what & when something works. I was going to buy the #4 wire and lugs until I saw your problems!! I think Scottyb's method looks best. Heating the cable sounds tricky in preventing the melting of the cable cover material. Also note: a torch has to be used in order to heat up that size lug and cable. I will await your success!!!
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Unread 03-15-2009, 09:45 AM   #17
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Default Re: soldering battery lugs

Reading this thread with a slight chuckle over all the troubles, solutions and engineering of cables here, I have but one question. This question is NOT meant to offend anyone involved, but asked ONLY for those considering this task...

"Does BUYING a complete set, already made sound any better now?"

Maybe some who are considering making their own may learn from this thread that premade sets may be worth the extra cash?

Factory EZGO - Bad Boy Buggy - Dixie Chopper Mowers
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Unread 03-15-2009, 10:46 AM   #18
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Default Re: soldering battery lugs

Sure if anyone sold a complete set! I have to change all the wires going from the HD solenoid, F/R switch also so I figured since I was doing all that I might as well do the batteries myself also. Didn't figure on running into this problem. Now I have all the parts but not the skill!

In response to earlier posts I did end up burning the sheath trying a similar method of heating both parts. Should I NOT be using rosin core? What do you guys use for solder??
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Unread 03-15-2009, 10:49 AM   #19
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Default Re: soldering battery lugs

Solid wire silver solder.....lead free.....get solder approved for domestic water pipe. It will be high quality......and enjoy the learning process. You will develope the skill and have a sense of accomplishment
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Unread 03-15-2009, 12:25 PM   #20
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Default Re: soldering battery lugs

If I just wanted a rebuilt cart I could go out and buy one. I want a cart that I have rebuilt myself. And like other projects from this forum I have found it is easier the next time around. Stay the course Extractor!! If soldering won't work for you crimping is a bail-out solution. And what they hey--If you save an average of 25cents an hour you are probably going too fast anyhow!!
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