Cutting and Crimping 2/0 Gauge

[hgvandy]

I have read a lot on these battery installations and not 100% confident in what I am doing. I bought a switch that can go to 1, 2, or both. I am hooking all the wires in like in the directions and the 2/0 gauge + wire from the engine is the one making me nervous. For it to fit on my switch, I need to cut the terminal off and put a 2/0 end with a 3/8 circular connector. I really don't want to cut this if I don't need to, but don't know any other way. Does anyone have any suggestions on getting around this? Also, I would rather not have to buy a big wire cutter and a crimper. Suggestions here would be appreciated.

[bzubke1]

I used a scissors to cut the wire and a vise grips to crimp the connector on.

[ian ashton]

A cheap alternative is a hacksaw to cut, and a hammer and piece of 2x4 to crimp. It won't be pretty, but it will get the job done.

Another alternative is to buy set screw rig terminals, rather than crimp.

[MLA]

A hacksaw is a good way to cut large gauge wire, as well as a rotary tool with a metal cutting disk.

For attaching the terminal lug, I would suggest soldering it over a crimp.

Here is a nice YT showing how to do it. http://www.youtube.com/watch?v=SXDkNMDDrBs

If you need to do this in the boat. I use vise-grips to hold the terminal an place it on a block of wood. Instead of a torch, I use a heatgun.

[hgvandy]

Thanks guys. I will give the hacksaw and 2x4 a go.

[Razzman]

I took mine down to the local battery dealer which was a mile away. For $1 an end he cut & crimped my lugs on the 1/0 cable with a hydraulic crimper.

[wolfeman131]

A hacksaw is a good way to cut large gauge wire, as well as a rotary tool with a metal cutting disk.
.

If you have a dremel style tool, go this route vs the hacksaw.

I like Razz's idea best.

[hgvandy]

I like Razz's idea as well, but just don't want to take out the cable and fish it back into the boat. I may do it just to make sure it gets done right. I have a week to think about it. I loved the soldering video as well. Very clean looking.

[Brianinpdx]

Hgv - I'd second Razz's idea of taking to a battery shop. MLA's video is a good one but unless you already have a torch and solder pellets and flux, your buying a bunch of stuff. The key to solder is making sure you have enough flux applied to the copper conductors and not OVER heat it. Doing so can create a resistive connection when it burns off the flux. To little heat and you run into the opposite problem. A proper solder joint will offer more surface contact.

On the crimp subject, make sure it gets crimped with a real crimp tool. The oversized crimp (hammer style) actually drive the metal sleeve back down into itself creating a physical pinch and not just a compression joint around the whole outside. So for a 1.00, I don't think you can beat the battery shop.

-Brian
Exile Audio

[lsvboombox]

If you are installing battery lugs you dont need to crimp just solder them.


Like this
http://www.youtube.com/watch?v=SXDkN...e_gdata_player

Just put something on the floor if you cant pull the wires out. You can do it with a much smaller pocket torch...