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Old 02-09-2013, 07:41 AM   #1
pcarenthuz
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Default New Cables - Crimp, Solder, Penetrox??

I'm making up some new cables for my 2001 TXT Series 48v upgrade. What do you all generally do here? Do you crimp only? Do you crimp and solder, or solder only? Do you ever use an anti-corrosive like Penetrox?

When making up new (engine starting) cables for my airplane a few years ago, I crimped and silver soldered along with heat shrinking. Of course, the FAA dictated what needed to be done here.

Thanks!

Pat
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Old 02-09-2013, 08:04 AM   #2
subby44
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Default Re: New Cables - Crimp, Solder, Penetrox??

What size are the cables? I would say 2 gauge solder would be great... a lot depends on what your running on the cart.. I have 4 g on mine and they are doing great...
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Old 02-09-2013, 08:35 AM   #3
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Default Re: New Cables - Crimp, Solder, Penetrox??

Quote:
Originally Posted by pcarenthuz View Post
..........
When making up new (engine starting) cables for my airplane a few years ago, I crimped and silver soldered along with heat shrinking. Of course, the FAA dictated what needed to be done here............
If it is good enough for airplanes, it ought to be good enough for golf carts, but only if you used high strand count welding cables.

I'm old school, so my cables have silver soldered terminal lugs and they are 2Ga because I'm an efficiency nut and they are sealed airtight because they are in a corrosive atmosphere. I'm using Kit#11 shown here: http://www.cartsunlimited.net/Batter..._Upgrades.html
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Old 02-09-2013, 09:13 AM   #4
pcarenthuz
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Default Re: New Cables - Crimp, Solder, Penetrox??

Johnnie, so you soldered only not soldered and crimped?

I bought 1 gauge high strand count welding cable. I'm going this route, well, because I could

Pat
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Old 02-09-2013, 10:33 AM   #5
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Default Re: New Cables - Crimp, Solder, Penetrox??

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Johnnie, so you soldered only not soldered and crimped?

I bought 1 gauge high strand count welding cable. I'm going this route, well, because I could

Pat
I bought them from Carts Unlimited and they are silver soldered only.

I'm not a big fan of crushing copper for both electrical and mechanical reasons.
Mechanically, a stress point is created where the copper stand is crushed and with flexing (vibration), that is where it will break.
Initially, both crimp and solder are about the same electrically and more or less stay that way as long as they stay airtight, but when the seal between the terminal lug and cable insulation starts leaking, the soldered connection will maintain its electrical integrity longer since there is no air gap between conductors. Granted, corrosion will migrate between solder bonded strands, like grass grows through cement, but it takes longer when there isn't an air gap.

I suspect the FAA regulation was a "Design by Committee"
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Old 02-09-2013, 10:55 AM   #6
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Default Re: New Cables - Crimp, Solder, Penetrox??

I work at a major corporate jet manufacture and every terminal lug is crimped only from 22 awg all the way to 5/0 awg on our jets.

I crimped my wires on my 72v cart.
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Old 02-09-2013, 12:07 PM   #7
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Default Re: New Cables - Crimp, Solder, Penetrox??

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I work at a major corporate jet manufacture and every terminal lug is crimped only from 22 awg all the way to 5/0 awg on our jets.

I crimped my wires on my 72v cart.
Like I said in post #3, I'm old school.

When I went through the NASA soldering school back in the early 70's, the mere mention of a crimped connector was considered blasphemy.
However, as it has been pointed out to me by a BGW forum member that no longer seems to be around, NASA now accepts crimped connections.

I find it interesting that FAA includes a caveat about under and over crimping in AC-43, Chapter-11, Paragraph-178 (Attached) and further comments that the connection is susceptible to high resistance between crimped terminal and wire due to corrosion build-up if not crimped tight enough.

To each their own, but I prefer silver soldered lugs on the high-current cables.
On the other hand, I have no problems with crimp type connections in the low amp circuits.
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Old 02-09-2013, 02:24 PM   #8
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Default Re: New Cables - Crimp, Solder, Penetrox??

That's too funny. You cite the same FAR reg the FAA FSDO inspector did when I was restoring the firewall on my Piper Comanche 3 years ago. I'm not an A&P so all my work was done under the watchful eye of an A&P. I think both crimping and soldering came into vogue as they are both viewed as providing a mechanical means for attachment with the view being soldering and crimping together are 2x as good. If they are both performed correctly there may be some logic to this -dunno...

I appreciate the views and insight. Thanks for sharing!

Pat
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Old 02-09-2013, 02:44 PM   #9
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Default Re: New Cables - Crimp, Solder, Penetrox??

In all honesty, if you've got the proper tools and do it right, either will suffice and maybe both will be better.
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Old 02-09-2013, 05:19 PM   #10
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Default Re: New Cables - Crimp, Solder, Penetrox??

AC-43 isn't a regulation, it's guidance. I can't find compliance to it like I can a CFR.

Johnnies quote:
"connection is susceptible to high resistance between crimped terminal and wire due to corrosion build-up if not crimped tight enough."

"If not crimped enough" is saying that this will occur on an improperly crimped connection. This can also happen on an improperly soldered connection too. A properly crimped (or soldered) connection will last a long time.

The high current cable terminations on a Gulfstream have grease inside the terminal and of course are properly crimped. They also have adhesive lined heat shrink for an airtight seal.

Either way will be fine on a golf cart. Worst problem that can happen is a fire and you can jump off if that happens. Can't say the same on an airplane at 50k feet.
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