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Unread 08-04-2011, 09:33 AM   #21
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Default Re: How to make New Battery cables for club cars

One thing for sure, there is an awful lot of show and tell going on and it is not all for the battery cable's benefit ....

A good secure connection sealed from the acidic environment is all that is required
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Unread 08-04-2011, 10:45 AM   #22
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Smile Re: How to make New Battery cables for club cars

Quote:
Originally Posted by essness View Post
Despite what the self proclaimed experts might say, more contact has never been a bad thing.
I'm always in favor of "more contact", be it golf cars or ...........

Have fun, Dave
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Unread 08-04-2011, 10:47 AM   #23
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Default Re: How to make New Battery cables for club cars

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I'm always in favor of "more contact", be it golf cars or ...........

Have fun, Dave
Me toooooo!
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Unread 08-04-2011, 11:29 AM   #24
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Default Re: How to make New Battery cables for club cars

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Originally Posted by scottyb View Post
Electron microscopes Remind me, Less we forget ~ It's a golf cart !!!


how many little tifs do i get in here when i say that.............its only a golfcart its not a space shuttle.......................................
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Unread 08-04-2011, 11:45 AM   #25
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Default Re: How to make New Battery cables for club cars

It's been said, These guys know that, silly... they are just playing with their microscopes and testers.
It's all good, the more people read this, the fewer carts will come into golf cart shops around the world with automotive battery cables on them.

Not everybody wants to make their own cables, but everybody should know the importance of having a good clean connection on the proper cable
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Unread 08-04-2011, 01:51 PM   #26
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Default Re: How to make New Battery cables for club cars

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as tight as you can seal with heat shrink.....fumes of H2So4..... Hydrogen sulfide..... seem to penetrate
the dual walled adhesive lined heat shrink i use creates a ridiculously tenacious grip on the jacket and lug. i didn't fully appreciate how well this stuff adhered until i tried removing some; its on there! so... in the unlikely event that the seal on the heat shrink is breached, the fumes would be met by a protective, conductive wax engineered specifically for the task of preventing corrosion from things like battery acid, oxygen, water, etc. it smells nice too!

but lets say both of those layers of protection failed and fumes, water, electrolyte, etc were allowed to contact the crimped connection... then what? catastrophe right? not quite! a proper crimp creates a "gas-tight" joint. in the absence of air and under extreme pressure, the mated metals are cold welded to form what is essentially a solid mass which is, to my knowledge, impenetrable by liquids or air.
-sj
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Unread 08-04-2011, 02:05 PM   #27
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Default Re: How to make New Battery cables for club cars

i found this 2/0 connector outside near my work area. it spent a few weeks in my battery bay, a month or two in storage, then roughly a month outside after i chopped it off to make up a cable for my new alltrax controller. plenty of rain & humidity the last month. notice the 1248 strands of 30awg.
-sj
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File Type: jpg crimps - 1.jpg (275.4 KB, 10 views)
File Type: jpg crimps - 2.jpg (458.1 KB, 13 views)
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Unread 08-04-2011, 02:17 PM   #28
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Default Re: How to make New Battery cables for club cars

this is a cross section cutaway view of the same crimped 2/0 lug and 1248 strands of copper after a light sanding with 400 then 1000 grit sand paper. the transition from the lug to the copper cable is slightly visible in this macro photo, however, it is indiscernible to naked eye.

i believe the small pits to the right side are chunks of jacketing material i failed to remove prior to crimping.
-sj
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File Type: jpg crimps - 3.jpg (270.9 KB, 13 views)
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Unread 08-04-2011, 02:46 PM   #29
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Default Re: How to make New Battery cables for club cars

and 3 more shots after a light polishing. the heatshrink & adhesive were not really cooperating with the polishing process, but i think you can pretty much see how tightly those strands are squeezed together. this is what 14.2 tons of pressure on a tinned copper lug & stranded copper cable produces; a nearly solid bar of copper.
-sj
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File Type: jpg crimps - 4.jpg (323.6 KB, 9 views)
File Type: jpg crimps - 5.jpg (154.6 KB, 9 views)
File Type: jpg crimps - 6.jpg (279.7 KB, 11 views)
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Unread 08-04-2011, 03:22 PM   #30
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Default Re: How to make New Battery cables for club cars

That's a really nice display, I just love seeing examples like that.

I do not know the answer to this, below is a resistance chart you can see by adding solder (zinc,lead,tin) you are adding lots of resistance silver solder much less.

Material ρ [Ω•m] at 20 C

Silver 1.5910−8
Copper 1.6810−8
Annealed Copper[note 2] 1.7210-8
Gold[note 3] 2.4410−8
Aluminium[note 4] 2.8210−8
Calcium 3.3610−8
Tungsten 5.6010−8
Zinc 5.9010−8
Nickel 6.9910−8
Lithium 9.2810−8
Iron 1.010−7
Platinum 1.0610−7
Tin 1.0910−7
Lead 2.210−7
Titanium 4.20x10−7
Manganin 4.8210−7
Constantan 4.910−7
Stainless steel[note 5] 6.89710−7
Mercury 9.810−7
Nichrome[note 6] 1.1010−6
Carbon (amorphous) 5 to 810−4
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