a thank you for lessons on how to make cables- before and after

csport

I want to say thank you for all of the help and recommendations you have given me!

I have to say, my gear heard, make anything, fabricate anything great guy came over to see what I was doing, and he saw the solder pellets and flipped out.
The when I dip the shrink wrap, he said that is one of the Coolest systems he has ever seen!
HE was laughing and seeing all of the places he is going to use these lugs, pellets and cables.

he did laugh when I was cutting the cables, my shoulder kept popping and he asked if I mind if he would cut the last four- I got the cable cutters at harbor freight and gave me a tip, to keep the cutter working better- put a little grease or vaseline and stick it in a plastic bag- kinda - like cosmolean

thanks again guys-

I do have a couple, questions, when I first went to went to hook up last wire and there was a little spark? when I went to hook it up the 2nd time- not spark? is that normal?

and lastly- my lights haven't worked after I got some work done at the dealer
I am going to pull out the key/forward- reverse/battery gauge panel and try to trace the wire
thanks guys

and yes you can make fun of me for having a sloppy battery compartment- tough to keep it clean when I had busted shoulders

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JohnnieB

Probably normal.
The spark is due to the filter capacitors in the controller being charged via the pre-charge resistor across the solenoid contacts.
The size of the spark depends on how long the batteries have been disconnected.
I suspect the first hook-up was after being disconnected for hours and the second hook-up was after only a few minutes.

crash test dummy

i'd check the power source first .. if you just put in new cables you may have forgot to wire in the lights or when the dealer had cart they may have pulled the power wire or fuse

csport

2005 Bad Boy Buggy/EZGo in disguise 48 volt 8x 6 volt Exides

and Yes JohnieB your are correct Sir

And My good Guy neighbor told me again on How cool the Solder pellets are- He kept saying, the pellets and the shrink wrap is one of the best anti oxidation methods he has seen

Do you use washers with the nuts on the posts?

Do you use any form of sealent to keep even more air from the conections?
thanks Guys

scottyb

The cable connections should be coated in dielectric grease (Vaseline works too) on all sides during installation to keep the acidic vapors given off during normal charging from corroding the cable end and connection.

crash test dummy

galloway

are you talking about the wytek solder slugs?

crash test dummy

way cool !!!

found this video

Kudaman

That's a lot easier then feeding an entire roll of soldier into the cable lug. Where do you get those pellets?

csport

from wytek

its like the video- very simple