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Building Battery Cables

July 10, 2012, 12:34:12 pm

I will admit I havn't learned all the tricks so I get enthused when I learn a new one (old dogs and ,,, )

The proper way to solder battery terminals

I have crimped then, looked at fancy tools to use, tried to get enough heat to solder, etc.
This looks like the simplest (if you can make up in the shop rather than a small cramped cubbyhole).

HTH

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Re: Building Battery Cables

Reply #1 – July 10, 2012, 12:44:18 pm

Nice video! Good tip. Crimping just makes an area of high resistance and is the first place to overheat with very high current draw like extended engine cranking in cold weather.

Pierce

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Re: Building Battery Cables

Reply #2 – July 10, 2012, 01:00:03 pm

Way Cool! I too have been looking for the best way to assemble some new battery cables without much success. Didn't want to invest in a crimper and have to carry it around.

Thanks Elliot! Karma to you.

see ya
ken

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Re: Building Battery Cables

Reply #3 – July 10, 2012, 01:13:30 pm

Oh yes, Agree with Pierce, in my world, we check voltage drop across the battery cables during the start cycle, one end to other end, max drop is .5 VDC drop. If more than the half volt drop, check & clean connections, add heavier cable or what ever it takes to stay under the half volt drop on the cable.
Battery cable & batteries are expensive, but cheap vs starters and no starting.
FWIW
Dave M

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Re: Building Battery Cables

Reply #4 – July 10, 2012, 06:09:09 pm

 I have always used 50/50 solder, flux , and the side burner of my bbq. If the copper looks real bad I just dip it in muriatic acid cleans it up real fast for solder .Gam

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Re: Building Battery Cables

Reply #5 – July 11, 2012, 01:27:32 am

Next door to Motorhomes of Texas is a battery store that made a new start battery ground 4/0 cable for me, using the same solder technique in the youtube video.

It was the first time, I saw a soldered battery cable terminal being put together and it sure looked secure and much better than crimping.

He filled the terminal end with many cut lengths of regular solder before heating it.

I once saw a truck parts store employee hammer a terminal end on a battery cable to make a poor quality crimp.

One of the things to think about is what direction/orientation (and bolt hole size) the terminal ends need to be in, as these cables are not twistable.

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Re: Building Battery Cables

Reply #6 – July 11, 2012, 06:51:58 am

Barry,
So correct on having a proper layout before you solder the cables IF you want a nice neat looking finished job, with a little thought and prior fitting, you can have a neat layout.  Use a magic marker to mark terminal and cable so you can duplicate what you like.  Nothing worse than a cable that had to be twisted & kinked to get hooked up.  Hope all is well
Dave M

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Re: Building Battery Cables

Reply #7 – July 11, 2012, 11:02:06 am

Hey, Elliott, perfect timing! I need to make up a short four ot cable to run between a shunt and the neg terminal. I was going to have somebody in town do the crimp but now I'm gonna give this deal a shot. Thanks.
jor

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Re: Building Battery Cables

Reply #8 – July 11, 2012, 11:06:58 am

Dell City sell some neat stuff. They are a bit higher than say Grainger.

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