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Electric Club Car Electric DS, and Precedent golf cars |
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08-04-2011, 08:33 AM | #21 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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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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08-04-2011, 09:45 AM | #22 |
Gone Wild
Join Date: Jul 2009
Location: Loveland, CO / Sun Lakes, AZ
Posts: 263
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Re: How to make New Battery cables for club cars
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08-04-2011, 09:47 AM | #23 |
Not your usual outlaw
Join Date: Oct 2008
Location: Near Lake Geneva, WI
Posts: 20,054
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Re: How to make New Battery cables for club cars
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08-04-2011, 10:29 AM | #24 |
The Last Moja Morani
Join Date: Jan 2007
Location: jumping from cart to cart
Posts: 8,975
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Re: How to make New Battery cables for club cars
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08-04-2011, 10:45 AM | #25 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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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 |
08-04-2011, 12:51 PM | #26 | |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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Re: How to make New Battery cables for club cars
Quote:
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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08-04-2011, 01:05 PM | #27 |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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 |
08-04-2011, 01:17 PM | #28 |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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 |
08-04-2011, 01:46 PM | #29 |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
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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 |
08-04-2011, 02:22 PM | #30 |
Gone Wild
Join Date: Apr 2011
Location: Texas
Posts: 600
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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 |
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