1/0 lugs with hydraulic crimper
Using the #70 hex dies in my new hydraulic crimper with 1/0 tinned copper lugs (not cast) and 1/0 cable. I squirt a little anti-oxidant around the lug hole, insert the cable and do a simple crimp. ...
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Well, there's absolutely no way 50 dies will work with these 1/0 lugs even after pre-crimping with the 70 dies. I can barely get them in between the 70 dies. Maybe they are just rather thick.
But I am getting better at eliminating the ears with the 70 dies. Crimp a bit, rotate, crimp some more and so on. Still ugly but strong.
I also pack the head of the closed lug with bits of flux-core solder. So much so that I have to force the copper wire all the way in. Then after crimping I flame the lug head until solder can be wicked in at the other end via the cable. It does wick, maybe my cables have coarse enough wire strands. And the insulation doesn't seem to melt or smoke at all; pretty tough stuff.
Unfortunately the heat shrink I bought for #6 cables isn't big enough for these 1/0s. So an electrical tape wrap it is. I will not be posting any pictures of these ugly lugs.
But I am getting better at eliminating the ears with the 70 dies. Crimp a bit, rotate, crimp some more and so on. Still ugly but strong.
I also pack the head of the closed lug with bits of flux-core solder. So much so that I have to force the copper wire all the way in. Then after crimping I flame the lug head until solder can be wicked in at the other end via the cable. It does wick, maybe my cables have coarse enough wire strands. And the insulation doesn't seem to melt or smoke at all; pretty tough stuff.
Unfortunately the heat shrink I bought for #6 cables isn't big enough for these 1/0s. So an electrical tape wrap it is. I will not be posting any pictures of these ugly lugs.
