Making battery cables

[Maine Sail]

This link: http://www.yandina.com/Soldering.htm goes into detail on how to solder battery cable terminals. Note that he also crimps the terminal before melting in the solder.

If solder will flow through the crimped fitting then you are simply not using a quality crimp tool. With a quality crimp tool (360 degree compression) solder will not flow into the crimp band area. I have taken the lugs I use, filled the end with sugar, made the crimp, then dropped it in a glass of water and let it sit many months (water actually evaporated because I forgot about it). I then drilled a hole and DRY sugar came out.

If you use a low quality tool then yes solder will flow into the crimped area.

 

[woodster]

Trouble with pre-fab is knowing the exact length to make them, too short and its' a disaster, too long and it probably means cutting it shorter and then having to crimp anyway. I guess I can pull the old ones measure them and then reinstall to keep the boat in service until I get them made up. I might try the swage tool just to see what happens with a piece of scrap wire. I made a short jumper out of #6 wire to go from the alternator to the battery cable terminal of the starter solenoid (per MaineSail's recommendation) using the local West swaging tool in the store, it was a really poor crimp, flattened the connector making "ears" on each side, I don't want to do that with battery cables, the wire is too expensive to screw it up.

the turnaround from order to when you get it from them is usually 3 to 4 days and is shipped free in the 48 states so having them out of commision is not that big of a deal just an excuse not to buy ...if you need them hooked up while you are waiting for the new ones just hook up your battery charger cable and your bilge pumps to keep the boat safe temporarily

 

[jibes138]

Ok woody you talked me into it. There is no more room in my garage for any more tools. My wife thinks garages are for cars, imagine that.

 

[Bad Obsession]

The beauty of making your own cables is that you know how they are made. You also know what they were made of and how good they are.

It was a very easy project to do this and worth while for me. I have run every wire in my boat and know how every connection was made. That is confidence in the system!

 

[All U Get]

Make friends with someone that has good tools.
All U Get

 

[capta]

I've been extremely happy with my inexpensive hydraulic crimper and it still works great after 5+ years. It is especially handy when I need to do a crimp alone, as it's hand size. I even use it on my davit wires.

However, these are the 'bad boys' when I want to crimp the big stuff and have someone to help. Each jaw has 4 size crimp settings so I can do 16 different sizes. 20+ years and counting.