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What type of cable lug is this?

gsingh

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I need a terminal/ lug like this but solid. I am trying to make cables for a battery maintainer. I also need cable that is that can handle 75amps and a positive and negative clamps.

Is there a website that sells all this? Would it be better to buy jumper cables and cut them and solder lugs on there? Would appreciate the help on this, as this is my first attempt at something like this.
 
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larry_g

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A welding supply or good auto parts store can fix you up. They have the lugs and the proper crimper to affix it to the wire. I would suggest the welding supply as they have probably better, more flexible wire. You may have to get your clamps at the auto supply though.

lg
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manwithtools

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They are called compression lugs. They take a specific tool and dies to crimp properly. Larry g gave you good advise - a good welding shop can make up custom cables like that without too much trouble.
 

Heavy Metal Doctor

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I do a fair bit of odd mobile power stuff like this at my work. My experience has been that if the exact size wire / terminals fall outside the usual battery cable or automotive wiring kinda parts, then you can probably get what you need from any place that does electrical supplies traditionally thought of for buildings / A/C power.
 

Bcom

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What kind of battery maintainer is this? Ive got a few different ones that only require a simple crimp style eyelet for basic auto wiring. Nothing this heavy duty.
 

doorfx

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In the forklift industry we do not solder, at least in my company. The constant movement of the lugs/connectors, heat and abuse cause the joints to fail too often. We have a SOP for all techs outlining the use of hydraulic crimps. We supply the tool.
 
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mikegt4

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I need a terminal/ lug like this but solid. I am trying to make cables for a battery maintainer. I also need cable that is that can handle 75amps and a positive and negative clamps.

Is there a website that sells all this? Would it be better to buy jumper cables and cut them and solder lugs on there? Would appreciate the help on this, as this is my first attempt at something like this.

75 amps seems to be waaaay more than a battery maintainer. What do you mean by "solid", a lug without a hole?

There are lots of places that sell battery cable wire and lugs. You can have them made to your specs.

My favorite DIY battery cable web site with a lot of information.
http://www.pbase.com/mainecruising/battery_cables
 

wrenchMONKEY_

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You can get those lugs at a welding supply store, marine shop or auto. Hell, even Lowes has some.

I crimp then solder them. Thats just me. Never had an issue. Make sure you crim then solder, not the other way around.

Everything from 2/0 with a 1/2 terminal for a Miller 252 ground clamp to 0GA with a 3/8 lug for Auto 12 Battery.
 
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gsingh

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75 amps seems to be waaaay more than a battery maintainer. What do you mean by "solid", a lug without a hole?

There are lots of places that sell battery cable wire and lugs. You can have them made to your specs.

My favorite DIY battery cable web site with a lot of information.
http://www.pbase.com/mainecruising/battery_cables

it a charger/maintainer. Used during updating software on vehicles. When I get to work tomorrow ill post pics of the old one that I have, so you can see what I am trying to replicate.
 

NKlamerus

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The reason to use stranded wire is flexibility. When soldering the solder wicks up the wire and makes it rigid and a stress point at the lug which is prone to break.

lg
no neat sig line
Ooooh, I thought it was a connection issue.

I guess that makes sense, I usually pre-shape the wire before soldering, haven't had an issue yet but I'll keep an eye out. (All for truck/boat wiring)
 

manwithtools

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The reason to use stranded wire is flexibility. When soldering the solder wicks up the wire and makes it rigid and a stress point at the lug which is prone to break.

lg
no neat sig line

Absolutely, a properly crimped connection is superior to solder in all ways. Use the proper tool and dies for the connector and never worry about it coming apart. This is a case where paying for someone with the right equipment to make up the connections is a good idea.

There are more than a few combinations as shown in the following chart:

http://www.tnb.ca/aus/pdfs/Color-Keyed-Wall-Chart.pdf
 

theoldwizard1

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Don't solder battery lugs !

The reason to use stranded wire is flexibility. When soldering the solder wicks up the wire and makes it rigid and a stress point at the lug which is prone to break.
Also some people will fill the cup of the lug with molten solder and then just stick the stranded wire in. This will result in a "cold" solder joint.
 
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pedrodagr8

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The reason to use stranded wire is flexibility. When soldering the solder wicks up the wire and makes it rigid and a stress point at the lug which is prone to break.

lg
no neat sig line
The solder can also alloys with the copper to form a more brittle hybrid alloy, making this transition point even more prone to failure than it normally would be.

Sent from my LGLS992 using Tapatalk
 

rlitman

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Why not crimp THEN solder? Isn't that how some car audio guys do it?

That would only work if that crimp lug had an observation port forward of the crimp where you could insert solder. Do not apply solder to the wire side.

In any case, solder should not flow into a properly crimped connection. A proper crimp should have no spaces for anything to enter. Not even air.

The problem is that it is hard to identify a good crimp visually from the outside, and damn near impossible to get it on your first try. I suggest that as you're learning how your dies work with a particular wire/connector pair, make a few crimps, slice them across the crimp, file them down, and look at the cross section. It is important that EVERY strand inside the crimped area is deformed (usually they roughly form hexagons). Strands that are still round mean that insufficient pressure to cold flow the copper was used, and oxygen can still find it's way in. Also look for micro cracking of the connector, gaps in places, etc.
 

mbshop

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If this a one use thing then just get the proper wire and lugs. Then just grind down a junk chisel. Then just wack the heck out of the chisel against the lug. Had to do that several times and I never had any issues. And yes, you do not need to solder these kind of connections.
 

manwithtools

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No need for solder in a properly executed crimp, it impossible to flow solder into a gas-tight crimp. See the earlier posts in this thread.

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Murphy4570

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I just solder with copper lugs myself. Had too many issues in the past with ******** bolt on terminals. Properly soldered connections work just fine IMO.

My method is to clamp the lug in a vise, and heat with an oxy-acetelyne torch. I push the solder into the lug while it is hot, and the heat melts it. While the solder is molten, I stick the prepared copper wire in and hold it there until the connection cools sufficiently to hold. After it is cold I give it a wiggle/pull test with my hands.

I have done this exact method on a couple of cars of mine, as well as the connecting lugs for a Meyers plow pump. Have had zero issues.
 

Hagatronics

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Engine

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