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03-01-2011, 07:22 AM
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#1 |
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Gone Wild
 Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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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03-01-2011, 02:51 PM
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#2 |
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Gone Wild
Join Date: Dec 2010
Posts: 488
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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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03-01-2011, 05:35 PM
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#3 |
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Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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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03-03-2011, 01:02 AM
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#4 |
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Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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Re: DS Cable Lugs
before...
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03-03-2011, 01:09 AM
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#5 |
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Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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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03-03-2011, 01:21 AM
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#6 |
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Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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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03-03-2011, 02:08 PM
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#7 |
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Gone Wild
Join Date: Dec 2010
Posts: 488
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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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