fine stranded high current wire
I replaced a defective starter on the VW today. In getting the darned thing out I busted the terminal lug on the battery cable. The wire is fine strand, like welding cable. So not having those very expensive crimp tools I went to HD to find a lug that would work. I ended up getting a T&B copper one that compresses the wires without forcing a set screw into the wires themselves. The screw pushes up against part of the lug, not touching the wires. The other part then compresses the whole bundle into a tight mass. Those solid models where the screw drives into the wires are the ones that break the wires, don't compress the whole bundle, and catch on fire. It starts good and hopefully will not give me any troubles. At work we use a lot of #6 fine stranded on the test bench. I use crimped ferrules there, as we are often changing the connections.
Be careful when using connectors, splices, and taps with fine stranded wire. If in doubt, use a ferrule.
A hammer crimp tool for larg cables is around $30, I don't really see a need to mess with the bolt on lugs. But for high current I prefer to solder them. All you need is propane torch, it's pretty easy. And really once you get up 1/0 it's probably the easiest unless you have a hydraulic crimp tool. Though those do look handy for quick repairs.
Originally Posted by KF7EJG
Years ago, a lady was taking her grandchild
to the doctor, and on the way, she
stopped the car for some reason, and it
wouldn't start again. The starter cable
had come off the lug, so I cleaned and
crimped it best I could, heated the joint
with my propane torch, flowed the solder in,
reconnected, and they were on their way.
Every splice in our house wiring is soldered.