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Unread 03-01-2011, 07:22 AM   #1
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Default DS Cable Lugs

about to order some fresh lugs for my '97 series DS... do these measurements & quantities sound right?

21 x 5/16" (batteries x 12, solenoid x 2, motor x 4, controller x 3)
4 x 1/4" (f&r switch x 4)
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Unread 03-01-2011, 02:51 PM   #2
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Default Re: DS Cable Lugs

2 of the F/R lugs are 1/4 but the other 2 lugs are attached with Hex machine screw #10 - 24 x 1/2 (smaller hole in the lug)
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Unread 03-01-2011, 05:35 PM   #3
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Default Re: DS Cable Lugs

nice one golfdog! of course, thats the one fastener i didn't check with the calipers! murphy almost got me!

0.05" is pretty significant, but im having a hard time finding 10-24 in 2/0... i think i have some long lugs that can possibly be drilled out. bummer!
-sj
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Unread 03-03-2011, 01:02 AM   #4
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Default Re: DS Cable Lugs

before...
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Unread 03-03-2011, 01:09 AM   #5
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Default Re: DS Cable Lugs

1st attempt...

i put the hole a little high. the bolt head clears the fillet, but the dimple in the top just barely misses making full contact with the post. f&r switch operates freely.
-sj
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Unread 03-03-2011, 01:21 AM   #6
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Default Re: DS Cable Lugs

2nd attempt...

i put the hole a little closer to the cable end. no dimple at the top and the post makes full contact with the lug. bolt head likely won't clear the fillet so i'll a: beat the lug into submission b: use a hex head bolt with a washer. i like this lug better than my first attempt. i need a deburring tool! gotta re-tin the bare copper as well.

i have the feeling a #10-24 fastener is gonna look rather silly sitting on the end of 2/0 hose.
-sj
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Unread 03-03-2011, 02:08 PM   #7
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Default Re: DS Cable Lugs

Looks like you're going to a lot of trouble to make it look original. I did the caveman like trick of hacking off the flat end of the old lug with #10 hole and soldered it onto the new lug over the 1/4 hole. Looks like it came from a farm, but works fine.
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