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Unread 03-16-2009, 05:40 PM   #31
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Default Re: soldering battery lugs

Having soldered hundreds of battery cables with success I offer this advise. Strip the end of the cable where the terminal will be soldered being careful NOT to touch the copper. Take the terminal and clean the inside with a wire brush until it is bright. DO NOT blow on the terminal to remove dust, just invert and tap to remove it. Coat the end of the cable with ROSIN flux and inset wire into end of terminal. Clamp terminal into vise at the lug and apply heat. Using ROSIN solder test until terminal is hot enough for solder to flow. At that point as the solder is flowing remove heat and fill terminal with solder. Allow to cool until solder becomes solid before moving connection. For a neat joint apply a small piece of "heat shrink" tube to cover connection. Looks like a factory cable connection. Acid core solder or acid flux should NEVER be used on electrical connections. Keep your work area clean and if the solder won't flow clean them again. Oils from your skin and moisture from your breath can and will prevent a solid joint. Solder joints should be bright and shiny, if they are dull you do not have a good joint. I hope this helps...Car53
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Unread 03-17-2009, 10:28 AM   #32
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Default Re: soldering battery lugs

Good ! pay it forward ->
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Unread 03-17-2009, 08:24 PM   #33
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Default Re: soldering battery lugs

If you need the terminals, I can sell you all you need. They are for 6-awg wire. The best crimpers I have ever had are a small bolt cutter I bought at agri-supply and used a small grinder to cut a grove in each side. This gives me a cutter and crimper in one tool. send message to rrgolfcart@bellsouth.net and I can send you pictures and a quote for lugs. If you really want to solder the crimps, do not use anything with a flame. Too much heat (pencil torch is 1300F). If you can find an old plumbers lead pot unit, it works very well. Solders are mostly Tin, Lead, Bismuth, and Antimony. The amount of Bismuth and antimony control most of the melting temp. ie 64% lead, 33% tin, 2.7% bismuth, and .3% antimony will melt at 420F. add .3% bismuth and it drops 18F.
ps: I am an retired component engineer from the electronics industry.
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Unread 03-17-2009, 10:17 PM   #34
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Default Re: soldering battery lugs

Thanks, bonduranth (and welcome to the site!)... I've committed to soldering the copper lugs right now given the investment in learning. An "old plumbers lead pot unit," is that for melting the solder in and then dipping the cable end into?
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Unread 03-17-2009, 10:27 PM   #35
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Default Re: soldering battery lugs

We have found that corrosion builds quickly under the shrink wrap mentioned above......For us it is better to coat with a spay protector 360 degrees and then install ...... Obviously this is a bit like skinning a cat.....I'm out
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Unread 03-18-2009, 07:26 AM   #36
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Default Re: soldering battery lugs

Quote:
Originally Posted by scottyb View Post
Obviously this is a bit like skinning a cat.....I'm out
That's for sure personally I prefer to start in the middle and pull both directions. that previous post was, well ah, I'll keep my mouth shut, Out.
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Unread 03-18-2009, 07:38 AM   #37
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Default Re: soldering battery lugs

Use liquid E tape to seal the ends.
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Unread 03-18-2009, 08:11 AM   #38
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Default Re: soldering battery lugs

Quote:
Originally Posted by Fishing Dude View Post
Use liquid E tape to seal the ends.
Liquid electrical tape? That sounds great.....

After some investigation it looks like I am off to the store for some liquid E coating = Thank you Fishingdude.
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Unread 03-18-2009, 08:33 AM   #39
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Default Re: soldering battery lugs

The pot sits above a kerosene burner that puts out a lot of heat. Old cast iron pipes that were used for sewer lines in houses years ago, were sealed with oakum then lead. The pot holds about 4 lbs of solder or lead. When heated, the pot stays hot, allowing you to dip the terminal and wire as a unit. A slight crimp will hold the lug on. Allow to cool, install, and coat with a good anti-corrosion. Electronic supply houses can get you 1 lb bars of solder that are used in solder wave equipment.
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Unread 03-18-2009, 10:22 AM   #40
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Default Re: soldering battery lugs

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Originally Posted by scottyb View Post
Liquid electrical tape? That sounds great.....

After some investigation it looks like I am off to the store for some liquid E coating = Thank you Fishingdude.


Fishing Dude, PETA = People Eating Tasty Animals
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