50mm to 95mm^2 Cable Crimpers

[brightspark]

soldering them is no good it stops the strands flexing and snaps fairly quick best crimped and heatshrink sleeving over them to give support and flexibility over a larger aeria

 

[Robotstar5]

It’s not so much the cables breaking down it’s between the lug and the cable. That oxidises.

The process induces incredibly high resistance too and is subject to repeated stress on the lugs.

That's down to poor crimping, the lug should match the cable size and the crimp tool should form lug tightly around the cable, if you sectioned the joint there should be no voids which is what creates high resistance.

 

[brightspark]

That's down to poor crimping, the lug should match the cable size and the crimp tool should form lug tightly around the cable, if you sectioned the joint there should be no voids which is what creates high resistance.

what i do is get some flex and strip the insulation off it and wrap it round the cable end if its not a tight fit in the lug then crimp it jobs a gudun

 

[Brad93]

That's down to poor crimping, the lug should match the cable size and the crimp tool should form lug tightly around the cable, if you sectioned the joint there should be no voids which is what creates high resistance.

What do you mean sectioned?

 

[Robotstar5]

What do you mean sectioned?

A different type of lug, but it shows what to look for, no voids between the strands once crimped.

 

[Brad93]

Will order some adhesive shrink tube.

still unsure what crimper to buy. I might see what, if any, crimpers the firm has. They must have something just probably been 10 years since they’ve been used.

 

[Hood]

A different type of lug, but it shows what to look for, no voids between the strands once crimped.

View attachment 269369

Going to have to give that a go and see what the Chinese crimper does, won't be as easy to see as that diagram due to the strand sizes but will still be interesting. I cut one off a cable the other day, not sure if I threw it in the skip or not but I will have a look and see.

 

[mtt.tr]

Going to have to give that a go and see what the Chinese crimper does, won't be as easy to see as that diagram due to the strand sizes but will still be interesting. I cut one off a cable the other day, not sure if I threw it in the skip or not but I will have a look and see.

thats how i came about the 10mm-16 lugs that i use, bought some from here and there until i found one that looked good inside.



im a hoot at a party honest

 

[Hitch]

Ive always used the heavy copper knock-ons, squat them down in the press.... if using the lesser flimsy lugs, do them in the press with a bit of tooling to squash in the lug.
The lugs outlast the actual claamps half the time.

https://www.spawelding.com/90mm-copper-knock-on-lug.html

 

[Hood]

Ive always used the heavy copper knock-ons, squat them down in the press.... if using the lesser flimsy lugs, do them in the press with a bit of tooling to squash in the lug.
The lugs outlast the actual claamps half the time.

https://www.spawelding.com/90mm-copper-knock-on-lug.html

Fancy buying some 70mm ones

 

[bigegg]

I have the cheapo hydraulic type and one of these hammer type, you just cant beat these manual crimpers at times.

It rattles around in the tool box just for that day....



https://www.ebay.co.uk/itm/Battery-...-/383807570985?_trksid=p2349624.m46890.l49292

place I worked had one of those mounted in a flypress

 

[zzr1200]

I've got one of these I use for battery leads on tractors and trucks. I paid quite a bit more than that though. But it looks the same

Snap-on or Mac????

 

[Brad93]

To give you an idea of the scale of the welding we are putting down a ton of wire in 48 hours.

 

[mtt.tr]

To give you an idea of the scale of the welding we are putting down a ton of wire in 48 hours.

That's like 1000kg.


No spots on me

 

[Brad93]

That's like 1000kg.


No spots on me

2200lbs?

 

[Hitch]

Twin wire sub arc?

 

[bigegg]

To give you an idea of the scale of the welding we are putting down a ton of wire in 48 hours.

WOW.

I was thinking at that sort of rate, you could almost 3d print everything I've ever built in about a week.
Wouldn't need any stock, just build it up from the wire

 

[Brad93]

Twin wire sub arc?

Triple head single wire.

 

[sako243]

soldering them is no good it stops the strands flexing and snaps fairly quick best crimped and heatshrink sleeving over them to give support and flexibility over a larger aeria

Fairly blanket statement there, as I mentioned in my post I've seen both fail equally regularly and my previous firm did a lot of extensive testing and trialling. We whittled down the crimp collection to a couple of dozen but the tooling costs still hit substantially into 6 figures (bordering on 7) so you can't really say we didn't use the proper crimps.

Whether it's soldered or crimped is largely irrelevant if the thing has proper strain relief. Adhesive heat-shrink is not really suitable as strain relief on something the size that @Brad93 is talking about. That'd I'd be looking at making up a simple mould and pouring some flexible epoxy or similar like you get with over moulded plugs.

Just a thought Brad can you replace the crimps with suitably sized DIN sockets or something similar? At least then you should be able to get some decent strain relief.

 

[Bornfree]

Snap-on or Mac????

No its Durite I bought it from an auto-electrical place I think it was about £40 +vat probably made in the same factory as these ones.