There are some auto, truck or golf cart shops that will supply the connectors, cables, heat shrink and even cut the cable and crimp on the wire terminals and/or battery clamps.
So this is where I bought all the supplies from. I first made up a spacing jig made out of a piece of wood and bolted on those battery adapter posts that are use to change the side mounts to standard post mounts. The post spacing is equal to the battery pack link spacing plus 1/8 inch. Place the battery clamps or terminals on the post and measure the length of cable needed between these two terminals. I use a long barrel heavy duty battery connection which has a long taper at the battery end. I find instead of measuring only the length of the barrel and between the space of the two battery connectors, I could add about 1/4 inch longer, because the copper strands will push tightly into this taper end. Make up one cable and test fit it for size. I then cut all the cable links to size. Circle cut the insulation on the ends of the cables, but do not slip the insulation off the end of the cables. Leave on until you are ready to install the battery or terminal connection on to the cable. This method prevents the fine wires from fraying. Next slip on the heat shrink on the cable that are using the battery clamps, because you cannot slip them on over these connectors. Install the battery or terminal connectors on the cable and temporary hold them on with a piece of tape. Take all these equipment back to the dealer where you bought all these supplies and they crimp all these fittings for you. Before crimping, place the link on the jig that has the two battery post and/or studs to correctly space the links. Also it prevents the connectors from pushing off a bit of the cables if you need exact spacing. The long barrel connections are double crimp. You first crimp at the wire end and than at the connection end which may be taper. If you first crimp at the taper connection end, this may cause the cable to push out of the connection. The crimping operation did not cost anything. Roland ----- Original Message ----- From: Lee Hart<mailto:[email protected]> To: L. Chris Hager<mailto:[email protected]> ; Electric Vehicle Discussion List<mailto:[email protected]> Sent: Tuesday, October 08, 2013 7:43 AM Subject: Re: [EVDL] For OO cable hook ups- need crimping tool L. Chris Hager wrote: > I have some fat cable onto which I have to crimp the ample connectors > I've bought to make the connections. I can't find a crimping tool... I bought mine from Waytek Wire www.waytekwire.com<http://www.waytekwire.com/>. They have quite a few models that will crimp large battery cables. I have a heavy duty one, (stock #460, $241.47) that has rotating dies to crimp #8 to 250 MCM (bigger than 4/0). They also have a budget model, Molex 19284-0034 (stock #497, $71.00) that has interchangeable dies and crimps sizes from #8 to 4/0. This one takes a lot of arm strength to operate. If you're cheap, they also have a hammer crimper (stock #462, $10.36). These depend on your skill, and you must TEST every connection you make to be sure it's good (mechanical pull test, and electrical resistance test). Any local electrician shop should have such a crimper, and could make a cable for you. Or, you can rent Bob Batson's crimper -- $30 is a good deal. Or, I'd be willing to crimp your lugs onto your cables with my crimper if they are loose so you could send them to me. -- Humanity is acquiring all the right technology for all the wrong reasons. -- R. Buckminster Fuller -- Lee A. Hart, http://www.sunrise-ev.com/LeesEVs.htm<http://www.sunrise-ev.com/LeesEVs.htm> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA<http://groups.yahoo.com/group/NEDRA>) -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20131008/2cf0678b/attachment.htm> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub http://lists.evdl.org/listinfo.cgi/ev-evdl.org For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA)
