I have been posting about some battery issues that came up yesterday. One of the projects that I have avoided is replacing my battery wires. I do most of my electrical work myself, and have gotten quite good at crimping and shrink wrapping. I have had years of success, and to date no failures of any electrical connections I have made. Where I have had an issue is crimping battery cable, the big stuff; 4/0 or 2/0. Where can I get a reasonably priced crimping tool, or does one exist. I thought I might have read somewhere that West Marine would lend one out if you purchase the wire and connectors, however my local store knows nothing about such a program. Am I at the mercy of a marine electrician to perform this type of work?
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Punch and hammer
I have had success, on several occasions over the years, in using a blunt punch, 3/16 or 1/4 and a hammer. Two depressions along one side hold the wire so tight that it cannot be removed. It is important that the lugs be copper and the correct size for the wire.
I have had success, on several occasions over the years, in using a blunt punch, 3/16 or 1/4 and a hammer. Two depressions along one side hold the wire so tight that it cannot be removed. It is important that the lugs be copper and the correct size for the wire.
Ahhh Battery clamps?!?!?!
You can buy ready made battery clamps at the auto parts store. The advantage is the clamp fits on the battery post and not the screw connector. More surface area to transfer the current!!! The wire just clamps on the clamp with two screws. This allows you to add wires as needed and not have to re-crimp resulting in one connection and not a stack on the screw post. Just make sure the wire is clean (no corrosion) and then either paint it with a commercial electrical paint or use lithium grease (my choice). The grease solution also allows for the addition of wires with out much fuss. This has worked for me for years but note that I have wet cells and check them frequently for fluid level and corrosion.
You can buy ready made battery clamps at the auto parts store. The advantage is the clamp fits on the battery post and not the screw connector. More surface area to transfer the current!!! The wire just clamps on the clamp with two screws. This allows you to add wires as needed and not have to re-crimp resulting in one connection and not a stack on the screw post. Just make sure the wire is clean (no corrosion) and then either paint it with a commercial electrical paint or use lithium grease (my choice). The grease solution also allows for the addition of wires with out much fuss. This has worked for me for years but note that I have wet cells and check them frequently for fluid level and corrosion.
Lug crimping tool
by Anchor marine works fine - costs about $50. If you aren't where you can hammer the thing shut, you can use a large "c" clamp instead. Also, it helps a lot if you make a clean cable cut in the first place. ChannelLock make a electrical wire cutter that will easily cut 2/0 cable very cleanly. Costs about $15 at any good tool store.
by Anchor marine works fine - costs about $50. If you aren't where you can hammer the thing shut, you can use a large "c" clamp instead. Also, it helps a lot if you make a clean cable cut in the first place. ChannelLock make a electrical wire cutter that will easily cut 2/0 cable very cleanly. Costs about $15 at any good tool store.
It's cheaper to go to a real battery shop.
It is cheaper to go to a real battery shop. They made a couple to mate up my two G31's and they charged me about $8 each. I could not puchase the materials for that price and they used their tools & labor too. Take the measurements and have them made up.
It is cheaper to go to a real battery shop. They made a couple to mate up my two G31's and they charged me about $8 each. I could not puchase the materials for that price and they used their tools & labor too. Take the measurements and have them made up.
I remember
reading about that "program" in a post somewhere..the details being buy, use, and return.
reading about that "program" in a post somewhere..the details being buy, use, and return.
I use one like this
I use one that looks like this. I crimped a #4 then cut it off and looked at the crimp. It looked like solid copper. Dan
I use one that looks like this. I crimped a #4 then cut it off and looked at the crimp. It looked like solid copper. Dan
Battery Terminals
Thanks for all of the replies. I would purchase pre-made or have them made up, however the existing openings into the battery compartment is too small to allow the number of wires with Lugs attached to fit. I like the liink for inexpensive tool.
Thanks for all of the replies. I would purchase pre-made or have them made up, however the existing openings into the battery compartment is too small to allow the number of wires with Lugs attached to fit. I like the liink for inexpensive tool.
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