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Bedlam's avatar
Bedlam
Moderator
May 01, 2017

Crimp, Solder, Crush

For a future project, I need to terminate 2ga, 4ga and 6ga wire. I already have most of the wire and a few bare copper lugs for this size wire but am looking for the best way to mate these two together. I plan to shrink tube over the barrels and wire after attachment for additional support. I am still awaiting some heavy amperage circuit breakers but am reluctant to purchase more terminations or specialized large gauge tools until I determine the best way to attach them. What works and what does not?

These bus bars were made from flattened copper tubing:
Truck Campers
  • ScottG's avatar
    ScottG
    Nomad
    May 01, 2017
    Quick test of a crimp; If you can move the wire back and forth and the ends of the wires coming out of the other side of the crimp don't move, it's tight enough. If they do move, it's too loose.
  • GordonThree's avatar
    GordonThree
    Explorer
    May 01, 2017
    theoldwizard1 wrote:
    GordonThree wrote:
    I used a cheap large gauge swaging tool and a cordless impact wrench to crimp my 4/0 gauge connections before soldering them.

    Where did you get your swaging tool ?


    Amazon. It's the basic kinds, two halves that are held together with big screws. I put the bigger half in a vice, assembled the cable end and then tightened down the other half. It wasn't an exact fit, so the tool doesn't close all the way but it's a sturdy connection.
  • theoldwizard1's avatar
    theoldwizard1
    Explorer II
    May 01, 2017
    GordonThree wrote:
    I used a cheap large gauge swaging tool and a cordless impact wrench to crimp my 4/0 gauge connections before soldering them.

    Where did you get your swaging tool ?
  • GordonThree's avatar
    GordonThree
    Explorer
    May 01, 2017
    I used a cheap large gauge swaging tool and a cordless impact wrench to crimp my 4/0 gauge connections before soldering them. Followed up with marine grade adhesive lined 3-1 heat shrink.
  • theoldwizard1's avatar
    theoldwizard1
    Explorer II
    May 01, 2017
    EXCELLENT ! Bus bars and bolts !! I would place a big Lexan shield over the whole thing.

    Crimping is the way to go especially on large gauge wire. It is difficult to get the terminal AND the wire to the proper temp for soldering. Lots of different crimp tools available. Don't "break the bank" on a hydraulic crimper unless you are planning on making LOTS of crimps.
  • thedavidzoo's avatar
    thedavidzoo
    Explorer II
    May 01, 2017
    We installed our own solar, lithium batteries, and inverter. Used one of these for lots of wire and lug sizes up to 2/0.

    https://www.amazon.com/gp/product/B003X51S00/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

    and this GREAT self-fusing silicone tape (I still can't get over this stuff!) Wrap tightly around the end of the lugs and up on the wire insulation some.
    https://www.amazon.com/gp/product/B00HWROLIG/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

    All worked like a charm!
  • hedge's avatar
    hedge
    Explorer
    May 01, 2017
    I use the ebay crimper, not sure it's any better than any other method but It makes a pretty crimp and haven't had any come undone yet.
  • cewillis's avatar
    cewillis
    Explorer
    May 01, 2017
    I made at least dozens (maybe more than 100)of connections using 2g wire. I use a hammer and chisel on concrete to crimp -- strong as any possible crimp. I then solder to make absolutely sure of the best electrical connection.
    Zero failures. Cheap and reliable.

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