Jumper Cables A Jumble Of Compromises
I've had an unused 30 feet of 4 AWG DLO cable sitting around for a number of years. I have decided to make jumper cables. DLO cable is the thickest and toughest insulation of them all and the conducto...
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I gave 1/2 of a set of jumpers to Celsi. From a jumper connected to a group 4 3-cell truck battery to a six inch wilton vise. It's for soldering starter motor leads with 100% lead which must be used in starters. I have the other ten feet which also have cheap copper coated steel parrot jaw clips. He has a pair of carbon 1/4" rods. The soldering is direct to the huge field coil steel starter case.
This is how I soldered the 350MCM lugs so many years ago in the gen shed. 350 MCM is a bit less than twice the size of 4/0 cable.
The wire in the small cable is authentic pure copper high strand count 8AWG. It was not easy nor cheap to find on eBay.
After modifications it will be connected to the Gigawatt 55 amp charger.
The steel parrot jaw clamp teeth will be lead coated just like the DLO 4AWG cables. And 12 AWG shunt wires within the jaws. Also to be multi coated with Bed Liner inside and out.
Aluminum conductor cannot be heat treated to eliminate brittleness. Aluminum's fatal flaw. Bend fine strand copper bundle back and forth until your finger's ache. Bend aluminum back and forth a few dozen times unil it fatigues and breaks. Vibration will also embrittle aluminum.
lightly used wire need not be concerned. Wire used for commercial jumping needs to be concerned, especially if coiled.
High voltage power transmission cable is aluminum. BUT It has rope stranded STEEL CABLE as a core.
Building any electrical assembly to tough grade specs is time consuming and a labor of love. Building to endure decades is an art form. This is Mexico. A place where garbage aluminum cables cost fifty dollars not $25 like in the states. I would be pleased if my cables last until the turn of 2100. My COVID delayed super charger for use in Alaska, has 2 chargers inside. The main charger is a 170 amp unit, the secondary is a 36 amp Megawatt for use with a tiny generator. It uses, owner supplied 2 AWG arctic grade charge lead cables. High speed blowers (brushless, German double ball bearing) can carry away an enormous amount of heat. This multi-charger project is missing mil-spec switches. Except for the 12 AWG SOOW power cable and battery leads color-coded 100% silicone wire is used throughout.
This is how I soldered the 350MCM lugs so many years ago in the gen shed. 350 MCM is a bit less than twice the size of 4/0 cable.
The wire in the small cable is authentic pure copper high strand count 8AWG. It was not easy nor cheap to find on eBay.
After modifications it will be connected to the Gigawatt 55 amp charger.
The steel parrot jaw clamp teeth will be lead coated just like the DLO 4AWG cables. And 12 AWG shunt wires within the jaws. Also to be multi coated with Bed Liner inside and out.
Aluminum conductor cannot be heat treated to eliminate brittleness. Aluminum's fatal flaw. Bend fine strand copper bundle back and forth until your finger's ache. Bend aluminum back and forth a few dozen times unil it fatigues and breaks. Vibration will also embrittle aluminum.
lightly used wire need not be concerned. Wire used for commercial jumping needs to be concerned, especially if coiled.
High voltage power transmission cable is aluminum. BUT It has rope stranded STEEL CABLE as a core.
Building any electrical assembly to tough grade specs is time consuming and a labor of love. Building to endure decades is an art form. This is Mexico. A place where garbage aluminum cables cost fifty dollars not $25 like in the states. I would be pleased if my cables last until the turn of 2100. My COVID delayed super charger for use in Alaska, has 2 chargers inside. The main charger is a 170 amp unit, the secondary is a 36 amp Megawatt for use with a tiny generator. It uses, owner supplied 2 AWG arctic grade charge lead cables. High speed blowers (brushless, German double ball bearing) can carry away an enormous amount of heat. This multi-charger project is missing mil-spec switches. Except for the 12 AWG SOOW power cable and battery leads color-coded 100% silicone wire is used throughout.
