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02-22-2017, 03:52 PM | #1 |
Gone Wild
Join Date: Sep 2015
Location: Cincinnati, Ohio
Posts: 1,354
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New Battery cables are here!!!
I can hardly contain my excitement!
TemCo 4 gauge welding cable (30' - 15' black / 15' red) 25 copper lugs with 5/16 hole 8' marine adhesive shrink tube (4' red / 4' black) Also got a Harbor Freight 8 ton crimper with dies. Had to sacrifice two lugs for testing. Looked like the #4 dies would destroy the lug, so I used a #2 die first, then an #0 die second. See pics below and let me know what you think. The gear Here is #2 die crimped. All the research I have done says that you do not want the "ears" after crimping as that will leave gaps for degradation and not as good current flow. Here is the #2 die with the end cut off. Looks like a solid copper wire, no gaps at all. Here is the #0 gauge die crimped. Looks really clean and solid. The heat shrink should work very well without the "ears" Here is the #0 crimp with the end cut off. Still looks like solid copper and no gaps. I think I'm going to go with the #0 die as it seems to be as solid and tight as the #2 die and looks cleaner. What do you think?? Ends cut off of both |
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02-22-2017, 04:38 PM | #2 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: New Battery cables are here!!!
It looks like the 1/0 die is still the best one for crimping 4ga lugs with the Harbour Freight crimper.
Here is another example of the 1/0 die used on 1/0, 2ga and 4ga lugs. http://www.buggiesgonewild.com/attac...er_samples.jpg |
02-22-2017, 05:08 PM | #3 |
Gone Wild
Join Date: Sep 2015
Location: Cincinnati, Ohio
Posts: 1,354
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Re: New Battery cables are here!!!
Looks like my choice was correct then.
Really does make a nice clean crimp |
02-22-2017, 05:14 PM | #4 |
Gone Wild
Join Date: Oct 2016
Location: Dundee quebec
Posts: 3,190
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Re: New Battery cables are here!!!
Ya gots da system! Gonna build to order? Why 4 gauge? Small tip. A thin smear of grease on the dies helps make a show quality crimp.
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02-22-2017, 05:26 PM | #5 |
Gone Wild
Join Date: Sep 2015
Location: Cincinnati, Ohio
Posts: 1,354
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Re: New Battery cables are here!!!
Went 4 gauge on purpose.
I can upgrade to 400 amp controller (when TahoeDawg talks me into it!) But I would need 2 gauge to upgrade more....so in my simple mind, I am saving myself from going all out with the 500 amp by having the excuse that "my cables can't handle 500 amps!" We'll see how well that works out for me. |
02-22-2017, 06:10 PM | #6 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,408
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Re: New Battery cables are here!!!
We used 650 amp controls for years with 4g cable sets ..... before we knew better
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02-23-2017, 01:01 PM | #7 |
Cave Dweller
Join Date: Apr 2013
Location: Always On The Move
Posts: 22,217
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Re: New Battery cables are here!!!
i went from stock cables to 4 ga for about a year , then 2 ga when i finally smartened up when running 700 amps
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02-23-2017, 01:11 PM | #8 |
Gone Wild
Join Date: Oct 2008
Location: Ga
Posts: 740
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Re: New Battery cables are here!!!
Nice Kashmir,
I spent 1.5 days after my rebuild and redid all my wires with 1O welding cable. Hammer crimped with crimping tool and silver solder all the ends. I then installed the adhesive type heat shrink with a hot air gun. I ran a all thread bolt through the OBC hole. The cables I had before were not 1O. Let me tell you I was blown away how cold everything is now and the increased take off and top end. I think some of my old wires from the F&R and controller were not sufficient for my 700 amp controller. |
02-23-2017, 01:22 PM | #9 |
Gone Wild
Join Date: Oct 2008
Location: Ga
Posts: 740
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Re: New Battery cables are here!!!
Pics of wires, I like your crimp tool Kashmir.
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02-23-2017, 02:22 PM | #10 |
Not Yet Wild
Join Date: Nov 2016
Posts: 9
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Re: New Battery cables are here!!!
Why crimp instead of using the drop in solder lugs?
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