Reply to Thread

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by jpump5

With the Deka crimper that I use ( which I
think is the same thing) you need to whack
it pretty good , several times , and the base
needs to be setting on something solid.
You can tell when the lug is crimped tightly by
the sound and feel when you hit it.

Same here. I have a 4x4" piece of 1/2" thick steel to set the crimper on and put the whole thing on the concrete floor. I hold the wire in place and use a lighter hit to secure the wire, then get my hand out of the way and give it a couple of good smacks with a small sledge hammer and that always does the trick.

Re: How to Properly Crimp 1/0 ultra flex cable ?

The best crimps on these soft copper barrels is the crimper that looks like a big pair of bolt cutters (or hydraulic). Far superior crimp.

Usually a bit too expensive to buy for occasional use though hence the reason for the hammer style ones being so popular.

I have a really nice one for #10, #8, #6 and #4 lugs each die rotates 4 positions and they lock in position.
They crush in 4 directions(dies form a square when closed)effectively reducing the I.D. all the way around evenly.

Re: How to Properly Crimp 1/0 ultra flex cable ?

This is the cable terminal crimper I made several years ago to mimic those found on Miller machines. Works with my 20T press or big up-n-down wrench.

Re: How to Properly Crimp 1/0 ultra flex cable ?

With the Deka crimper that I use ( which I
think is the same thing) you need to whack
it pretty good , several times , and the base
needs to be setting on something solid.
You can tell when the lug is crimped tightly by
the sound and feel when you hit it.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by Jonath108

Thank you,
I am able to pull the cable out with not much force. I am using long barrel 1/0-2/0 copper lugs. I do put double crimps as well.
I do not have much room when I push the bare multi stranded wire into the lug. I am also getting grooves at the underside of the lug from the Temco hammer crimp tool. I am not sure if that is also a problem.

I've had and used this type of crimper since 1985, mine works great, gives a tight crimp that can be shrunk wrap easily, I have used it in a vise or hydraulic press, it has always given good results

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by smithdoor

It is stud size on most welders.
The nut holds the copper connector you just solder to cable.

Most studs use 1/2" brass .

The low cost welders will almost any size as found out.
After I retired and sold my business I purchased a small welder from Harbor Frieght it used monkey threads aka metric.

Dave

FYI if the monkey threads fail or nut runs away I plan to real American threads 1/2" NC like all American welders use.

Thank you

Re: How to Properly Crimp 1/0 ultra flex cable ?

It is stud size on most welders.
The nut holds the copper connector you just solder to cable.

Most studs use 1/2" brass .

The low cost welders will almost any size as found out.
After I retired and sold my business I purchased a small welder from Harbor Frieght it used monkey threads aka metric.

Dave

FYI if the monkey threads fail or nut runs away I plan to real American threads 1/2" NC like all American welders use.

Originally Posted by Jonath108

can you explain how you use 1/2” NC brass bolts ? I am sure the studs are just steel as well as the washer and nut.
thanks

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by smithdoor

One I found to handy is box of brass 1/2" NC nuts. If lose one it a pain to find one.
But looking for box on internet can save day.
I even have brass All-thread for new studs.
My shop was over 30 minutes from closest hardware store, it saved a few long trip to have few replacement parts in shop.

Dave

can you explain how you use 1/2” NC brass bolts ? I am sure the studs are just steel as well as the washer and nut.
thanks

Re: How to Properly Crimp 1/0 ultra flex cable ?

maybe go down on lug size and try something like a #0 to #1 crimp lug to see if its a better fit. The wire should be a little snug going in.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by Welder Dave;8814That 072

I was agreeing with you. I think it's also important to only strip the insulator back till it fits up against the lug. Have seen a lot of cables showing the exposed copper and it can/will cause premature failure.

That about stripping only enough and adding a section of good heat shrink tubing over the stem of the lug is also a good idea.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by M J D

I'm well aware of that, he's using crimp on lugs. Some of the lugs are sized for more than 1 size cable. If they don't fit fairly snug in the crimp on lug they won't crimp properly and hold securely. In this case the shim would take up some of the space, allowing a proper crimp.

I was agreeing with you. I think it's also important to only strip the insulator back till it fits up against the lug. Have seen a lot of cables showing the exposed copper and it can/will cause premature failure.

Re: How to Properly Crimp 1/0 ultra flex cable ?

One I found to handy is box of brass 1/2" NC nuts. If lose one it a pain to find one.
But looking for box on internet can save day.
I even have brass All-thread for new studs.
My shop was over 30 minutes from closest hardware store, it saved a few long trip to have few replacement parts in shop.

Dave

Originally Posted by Jonath108

Thanks for all of your advice !

Re: How to Properly Crimp 1/0 ultra flex cable ?

Thanks for all of your advice !

Re: How to Properly Crimp 1/0 ultra flex cable ?

You may want think about using elevators. The cables are lead connections.
Remember you smart phones use solder.

If like smashing things use crimp type using a hammer.

Dave

Originally Posted by Xsbank

Crimping is way better than soldering, the crimp (ahem) welds the cable strands into one lump on the lug. Soldering, you are gluing the cable in place with acid, two kinds of metal, one of which can fracture.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Crimping is way better than soldering, the crimp (ahem) welds the cable strands into one lump on the lug. Soldering, you are gluing the cable in place with acid, two kinds of metal, one of which can fracture.

Re: How to Properly Crimp 1/0 ultra flex cable ?

I agree with smithdoor. I solder all mine with acid core solder then soak it in strong baking soda water to neutralize any acid that worked up in the strands.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by Welder Dave

Several stingers and ground clamps come with a piece of thin shim stock to wrap around the cable to make it fit tighter. A good crimp or tight bolt is usually all you need. Soldering isn't common on simple connections.

I'm well aware of that, he's using crimp on lugs. Some of the lugs are sized for more than 1 size cable. If they don't fit fairly snug in the crimp on lug they won't crimp properly and hold securely. In this case the shim would take up some of the space, allowing a proper crimp.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by M J D

I would try and jam some copper shim material in there. A piece cut out of copper tubing works well. You want the absolute tightest fit possible before crimping. Tinning the end with solder may help but I'm not a fan of solder as I've seen connections get hot and fail but thats mainly a battery cable thing.

Several stingers and ground clamps come with a piece of thin shim stock to wrap around the cable to make it fit tighter. A good crimp or tight bolt is usually all you need. Soldering isn't common on simple connections.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by smithdoor

One advantage of soldering is you reuse the lug.
But after using solder I no longer need to replace any lugs.

One problems I had was employees will do a renumbered on anything this includes crimp lugs.
In most shops have a torch handy so take a minute to solder.

Dave

FYI To big of lug just add more solder will do.

Thank You

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by danielplace

Your barrel is too big.

Fine strand wire is more compact than the wire those were made to fit .

Cut some strands off and put them in with the end to tighten it up in there before you crimp it. The barrel needs to be snug on the strands before you crimp. Go down one size and it may fit properly.

Many electrical supply houses rent real press tools. Swing in and ask if you could make a couple crimps with one. No comparison in results but the wire still has to fit the barrel snug first. Sloppy wire fit makes for a sloppy crimp.

Thank you

Re: How to Properly Crimp 1/0 ultra flex cable ?

One advantage of soldering is you reuse the lug.
But after using solder I no longer need to replace any lugs.

One problems I had was employees will do a renumbered on anything this includes crimp lugs.
In most shops have a torch handy so take a minute to solder.

Dave

FYI To big of lug just add more solder will do.

Originally Posted by danielplace

Your barrel is too big.

Fine strand wire is more compact than the wire those were made to fit .

Cut some strands off and put them in with the end to tighten it up in there before you crimp it. The barrel needs to be snug on the strands before you crimp. Go down one size and it may fit properly.

Many electrical supply houses rent real press tools. Swing in and ask if you could make a couple crimps with one. No comparison in results but the wire still has to fit the barrel snug first. Sloppy wire fit makes for a sloppy crimp.

Re: How to Properly Crimp 1/0 ultra flex cable ?

I would try and jam some copper shim material in there. A piece cut out of copper tubing works well. You want the absolute tightest fit possible before crimping. Tinning the end with solder may help but I'm not a fan of solder as I've seen connections get hot and fail but thats mainly a battery cable thing.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Your barrel is too big.

Fine strand wire is more compact than the wire those were made to fit .

Cut some strands off and put them in with the end to tighten it up in there before you crimp it. The barrel needs to be snug on the strands before you crimp. Go down one size and it may fit properly.

Many electrical supply houses rent real press tools. Swing in and ask if you could make a couple crimps with one. No comparison in results but the wire still has to fit the barrel snug first. Sloppy wire fit makes for a sloppy crimp.

Re: How to Properly Crimp 1/0 ultra flex cable ?

Originally Posted by smithdoor

Very good luck

Dave

Thank You !

Re: How to Properly Crimp 1/0 ultra flex cable ?

Very good luck

Dave

Originally Posted by 12V71

You're going to get grooves... hit it hard, then hit it harder. I've been using that style crimper for 40 years, there is no "overdoing it".