How to Properly Crimp 1/0 ultra flex cable ?

[Jonath108]

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

[CAVEMANN]

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

[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.

[duaneb55]

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.

[danielplace]

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.

[G-ManBart]

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.