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Old 04-06-2016, 12:14 PM   #11
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Solder makes your best connection.


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Sorry, but "Best" and solder and electrical connections can be looked at a number of ways. I look at it differently.

In industry, very, very, few large gage cable terminations are done using solder. Soldering a termination is highly dependent on several variables that need to be controlled with the biggest one being the skill, training and motivation of the human doing the soldering. The may not fully apply to a personal/casual/hobby activity like RV mods done by the owner or a buddy but it is still a significant variable.

Soldering is not always the best and can all to often result in joints that look good but result in damaged insulation from heat, wicked solder that results in a long, mechanically problematic connection, no true mechanical bond between the connector and the cable and personal exposure to toxic fumes.

from my perspective, crimping is the way to go for wire/cable terminations.

Cheers!
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Old 04-06-2016, 12:20 PM   #12
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Sorry, but "Best" and solder and electrical connections can be looked at a number of ways. I look at it differently......
True, you have to know about these things, as well as have experience soldering. However, the same can be said of crimping with substandard tools or incomplete solutions.

Rosin core solder is quite safe and these cables are so big that they take to it quite well. Of course...heat the lug and not the cable and the lugs are really big as well. But then I have soldered a lot of things in the past.
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Old 04-06-2016, 02:07 PM   #13
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Our utility crews use a Burndy tool MRC840 Burndy HYTOOL Rotating Die Crimp Tool, #8 - 4/0 AWG, Cu. A bit pricy, but made for the task.
............. Swampy
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Old 04-06-2016, 02:14 PM   #14
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Do both, crimp and solder.
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Old 04-06-2016, 02:15 PM   #15
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Here is a possible solution:
Straight Barrel Fusion Battery Terminals - Positive
Terminals and lugs already loaded with solder.
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Old 04-06-2016, 03:11 PM   #16
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Check the local auto parts door. When I replaced the cable terminals on my Hummer years ago, the local auto parts store rented me the tool for a few hours for five bucks.
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Old 04-06-2016, 03:18 PM   #17
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I bought one of these TEMCo Hydraulic Cable Lug Crimper TH0006 - 5 US TON 12 AWG to 00 (2/0) Electrical Terminal Cable Wire Tool Kit 5 YEAR WARRANTY through amazon. But I had a lot of terminals to crimp.

gw
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Old 04-06-2016, 03:19 PM   #18
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Originally Posted by ScottBrownstein View Post
True, you have to know about these things, as well as have experience soldering. However, the same can be said of crimping with substandard tools or incomplete solutions.

Rosin core solder is quite safe and these cables are so big that they take to it quite well. Of course...heat the lug and not the cable and the lugs are really big as well. But then I have soldered a lot of things in the past.
Scott, I think both of us have soldered a lot of things in the past. I started in 1964 and I'm not old enough for Social Security (yet)!

And that is it. If you have experience and patience and a bit of knowledge, it can work out ok. BUT: decent tools and a little bit of technique allow almost anybody to make a great crimped joint!
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Old 04-06-2016, 04:09 PM   #19
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I us this this hydraulic crimper from Amazon: Robot Check

For $40 it works great for the home handyman. I don't think it would hold up to daily use.
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Old 04-06-2016, 04:18 PM   #20
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Might check with an Industrial electrical contractor to make the crimps if it is a one time deal.
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