[EVDL List]

A good cable terminal crimper is a hex shape. A 6 corner die. You can
modified a hammer clamp by welding on a segment of a heavy duty impact 6
corner socket.

A good wire terminal or battery clamp terminal is a heavy duty one that does
not have a small hole at the connection end. This is normally use for a
solder indication. If you terminals have a hole in it, than make sure the
heat shrink covers that hole.

It is best to make two crimps on the barrel of the wire terminal or battery
clamp barrel. If you are using a heavy duty terminal that has a long
barrel, then you crimping dies should be 3/8 inch wide. If you use the
short barrel terminal than the die should be 1/4 inch long.

Cut a piece of the 2/0 cable and strip some insulation from the end of the
wire. Take it to a auto parts store size the wire to impact type of socket.
The wire should just insert nicely into the socket, not tight with the wire
strands only touching the 6 points in the socket. This will be the correct
size to make you die.

Now cut a segment off the die, so you have either a finish 1/4 or 3/8 inch
wide die. Normally I cut it about 1/32 of a inch wider, so I can dress up
and smooth the cut sides with a file.

Cut the segment in two parts where you have two 3 corner shapes in each
segment. You now weld or have it welded to the impact points on the hammer
crimper.

You do your first crimp on the terminal barrel about 1/8 inch from the wire
entry end. Then do the next crimp about 1/8 inch from the first crimp. The
reason why it best to crimp this way, is that the spade end or the ring end
is taper down, and sometimes if you crimp this end first, it may push the
cable back out of the barrel.

If the barrel is really long, which we may use in some industrial
applications, there may be three guild line segments for make three crimps,
first crimp the center, then the wire entry section and than the spade or
ring end section last.

A good terminal will have guild lines to show where you place the dies of
the crimper.

If you are making battery links, be sure you slide on a heavy duty heat
shrink that has a sealant in it first, because you may not get it over the
battery post clamps.

Roland








----- Original Message -----
From: "wguinon" <xxx@xxx.xxx>
To: <xxx@xxx.xxx.edu>
Sent: Tuesday, April 01, 2008 7:35 PM
Subject: [EVDL] Hammer Crimper


>
> Is there a preferred brand of hammer crimper for attaching copper battery
> terminals to 2/0 cable? The pictures on the web are not that clear but
> there
> seems to be one type with a pointed sliding part and another with a wedge
> shape.
>
>
> --
> View this message in context:
> http://www.nabble.com/Hammer-Crimper-tp16434990p16434990.html
> Sent from the Electric Vehicle Discussion List mailing list archive at
> Nabble.com.
>
> _______________________________________________
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I think the general preference on this list is to NOT use a hammer crimper.

However, if you must, I think this one has the potential to do the best
crimp:
http://www.amazon.com/Ancor-701010-Marine-Grade-Electrical/dp/B000NHZZDW

Note: this is a HEX hammer crimper

>
> Is there a preferred brand of hammer crimper for attaching copper battery
> terminals to 2/0 cable? The pictures on the web are not that clear but
> there
> seems to be one type with a pointed sliding part and another with a wedge
> shape.
>
>
> --
> View this message in context:
> http://www.nabble.com/Hammer-Crimper-tp16434990p16434990.html
> Sent from the Electric Vehicle Discussion List mailing list archive at
> Nabble.com.
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>


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[quote]wguinon wrote:
> Is there a preferred brand of hammer crimper for attaching copper battery
> terminals to 2/0 cable? The pictures on the web are not that clear but there
> seems to be one type with a pointed sliding part and another with a wedge
> shape.
>
>
>
The best deal I've seen is renting the ratcheting crimper from evsource:

http://evsource.com/tls_cabling_tools.php

but you can buy the hammer crimper on that page if you really want to go
that route.

Cory Cross

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> However, if you must, I think this one has the potential to do the best
> crimp:
> http://www.amazon.com/Ancor-701010-Marine-Grade-Electrical/dp/B000NHZZDW
>
> Note: this is a HEX hammer crimper

Disregard, on closer examination this is NOT a hex crimper.

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[quote]On 1 Apr 2008 at 13:46, Peter VanDerWal wrote:

> http://www.amazon.com/Ancor-701010-Marine-Grade-Electrical/dp/B000NHZZDW
>
> Note: this is a HEX hammer crimper

I may be mistaken, but that looks exactly like one I own, and mine does not
make hex crimps. It just pokes down a small area in the middle of the lug.
Not very secure, but it seems to works OK for the #6 (or is it #4?) stuff in
my Elec-Trak (which is why I got it).

I wouldn't use it or recommend it for cables in a road EV. I have a good
hammer crimper for that purpose, and it's been fine for up to 500 amps.
Beyond that probably a lever action hex crimper would be better, if you have
the muscles to use it (I don't).

David Roden - Akron, Ohio, USA
EVDL Administrator

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If not a hammer crimper, then what - a power crimper?

Solder?

I'm wondering what the challenge of soldering is? Not
enough heat due to dissipation by the lug and thick
cable?

What do people use to solder? Is a plumber's torch
overkill? Is there special solder for this job?
In-core flux or separate paste?

Is it best to get pre-tinned lugs, or is a good
cleanout of the lug opening with a wire brush enough?

Any web link references would be great.

Thanks,

Scott



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[quote]Roland Wiench wrote:
> A good cable terminal crimper is a hex shape. A 6 corner die. You can
> modified a hammer clamp by welding on a segment of a heavy duty impact 6
> corner socket.
>
I have a large Burndy MY29 manual crimper (two handles about 20" long).
It makes a dimple in the terminal ,which I think is similar to the
hammer crimper. It is adjustable for different gauges. Is this not a
recommended crimper?

- SteveS

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We at one time use this type of crimper, but the specifications call four a
four way crimp. We got by using this type by turning it four times make
four 1/4 inch indentations in one location and then another four
indentations on long barrel cable terminals.

It is now required to have a quality control inspection of a ratchet crimper
with a fix torque rating.

Roland




----- Original Message -----
From: "SteveS" <xxx@xxx.xxx>
To: "Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
Sent: Wednesday, April 02, 2008 8:33 PM
Subject: Re: [EVDL] Hammer Crimper


[quote]> Roland Wiench wrote:
> > A good cable terminal crimper is a hex shape. A 6 corner die. You can
> > modified a hammer clamp by welding on a segment of a heavy duty impact 6
> > corner socket.
> >
> I have a large Burndy MY29 manual crimper (two handles about 20" long).
> It makes a dimple in the terminal ,which I think is similar to the
> hammer crimper. It is adjustable for different gauges. Is this not a
> recommended crimper?
>
> - SteveS
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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What about modifing a pair of bolt cutter jaws to crimp lugs of one size,
maybe even welding the 6 point socket deal in there for a 6 point crimp?

----- Original Message -----
From: "Roland Wiench" <xxx@xxx.xxx>
To: "Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
Sent: Thursday, April 03, 2008 12:38 AM
Subject: Re: [EVDL] Hammer Crimper


> We at one time use this type of crimper, but the specifications call four
> a four way crimp. We got by using this type by turning it

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That also works, but you need a ape to help you crimp the heavy duty cable
terminals. Use the very large bolt cutters that has a double action jaw
design. I have bent the smaller 24 inch lever arms together.

Roland


----- Original Message -----
From: "Josh Creel" <xxx@xxx.xxx>
To: "Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
Sent: Wednesday, April 02, 2008 10:43 PM
Subject: Re: [EVDL] Hammer Crimper


> What about modifing a pair of bolt cutter jaws to crimp lugs of one size,
> maybe even welding the 6 point socket deal in there for a 6 point crimp?
>
> ----- Original Message -----
> From: "Roland Wiench" <xxx@xxx.xxx>
> To: "Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
> Sent: Thursday, April 03, 2008 12:38 AM
> Subject: Re: [EVDL] Hammer Crimper
>
>
> > We at one time use this type of crimper, but the specifications call
> > four
> > a four way crimp. We got by using this type by turning it
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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