lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car
Electric Club Car Electric DS, and Precedent golf cars



Post New Thread  Reply
 
Thread Tools Display Modes
Old 08-04-2011, 08:33 AM   #21
scottyb
Happy Carting
 
scottyb's Avatar
E-Z-GO
 
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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
scottyb is online now   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 08-04-2011, 09:45 AM   #22
carguy
Gone Wild
 
carguy's Avatar
Club Car
 
Join Date: Jul 2009
Location: Loveland, CO / Sun Lakes, AZ
Posts: 263
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
carguy is offline   Reply With Quote
Old 08-04-2011, 09:47 AM   #23
essness
Not your usual outlaw
 
essness's Avatar
Yamaha
 
Join Date: Oct 2008
Location: Near Lake Geneva, WI
Posts: 20,054
Default Re: How to make New Battery cables for club cars

Quote:
Originally Posted by carguy View Post
I'm always in favor of "more contact", be it golf cars or ...........

Have fun, Dave
Me toooooo!
essness is offline   Reply With Quote
Old 08-04-2011, 10:29 AM   #24
shadowman
The Last Moja Morani
 
shadowman's Avatar
Club Car
 
Join Date: Jan 2007
Location: jumping from cart to cart
Posts: 8,975
Default Re: How to make New Battery cables for club cars

Quote:
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.......................................
shadowman is offline   Reply With Quote
Old 08-04-2011, 10:45 AM   #25
scottyb
Happy Carting
 
scottyb's Avatar
E-Z-GO
 
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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
scottyb is online now   Reply With Quote
Old 08-04-2011, 12:51 PM   #26
sonicj
Gone Wild
 
sonicj's Avatar
Club Car
 
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
Default Re: How to make New Battery cables for club cars

Quote:
Originally Posted by ForBruce View Post
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
sonicj is offline   Reply With Quote
Old 08-04-2011, 01:05 PM   #27
sonicj
Gone Wild
 
sonicj's Avatar
Club Car
 
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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
Attached Images
File Type: jpg crimps - 1.jpg (275.4 KB, 10 views)
File Type: jpg crimps - 2.jpg (458.1 KB, 13 views)
sonicj is offline   Reply With Quote
Old 08-04-2011, 01:17 PM   #28
sonicj
Gone Wild
 
sonicj's Avatar
Club Car
 
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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
Attached Images
File Type: jpg crimps - 3.jpg (270.9 KB, 13 views)
sonicj is offline   Reply With Quote
Old 08-04-2011, 01:46 PM   #29
sonicj
Gone Wild
 
sonicj's Avatar
Club Car
 
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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
Attached Images
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)
sonicj is offline   Reply With Quote
Old 08-04-2011, 02:22 PM   #30
gaminde
Gone Wild
Club Car
 
Join Date: Apr 2011
Location: Texas
Posts: 600
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 1.59×10−8
Copper 1.68×10−8
Annealed Copper[note 2] 1.72×10-8
Gold[note 3] 2.44×10−8
Aluminium[note 4] 2.82×10−8
Calcium 3.36×10−8
Tungsten 5.60×10−8
Zinc 5.90×10−8
Nickel 6.99×10−8
Lithium 9.28×10−8
Iron 1.0×10−7
Platinum 1.06×10−7
Tin 1.09×10−7
Lead 2.2×10−7
Titanium 4.20x10−7
Manganin 4.82×10−7
Constantan 4.9×10−7
Stainless steel[note 5] 6.897×10−7
Mercury 9.8×10−7
Nichrome[note 6] 1.10×10−6
Carbon (amorphous) 5 to 8×10−4
gaminde is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car


Thread Tools
Display Modes


Similar Threads
Thread Forum
How To make New Battery Cables Electric EZGO
1/0 Battery Cables to 6 AWG Motor Cables Electric EZGO
Does anyone make 4 gauge cables for 36V Club Car? Golf Carts and Parts
yamaha g-16 engine with all wiring and cables make an offer Golf Carts and Parts
Club Car battery cables Electric Club Car


All times are GMT -5. The time now is 05:05 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.