Building my own batterty cables

[deltabravo]

I'm working on installing an inverter and new batteries in my RV and I needed new battery cables. I am using a TEMco Industrial TH0005 Crimper, which I really like.

Here's how I built the cables

[deltabravo]

Here's a little more detail on the crimpers: Unboxing video / intro

[deltabravo]

I have quite a few pieces of cable left over from adding inverters to all my RVs, so it was time to buy my own crimper and make use of the cable I've had on hand.

[time2roll]

Super_Dave wrote:
I go to Amazon and buy cables already made up in 1' increments.

About any size, any length, any termination.

https://www.genuinedealz.com/collections/custom-cables

[Timmo_]

I'm in the "go to welding shop" camp. Had to create a "cable manifold" of sorts when I went with a pair of 6 volt golf cart batteries. Went with the biggest gauge they had. LOL, they charged me a 12 pack of beer.

[Super_Dave]

I go to Amazon and buy cables already made up in 1' increments.

[deltabravo]

duplicate

[deltabravo]

philh wrote:
how many amps are you running thought that cable, a bazillion?

Nope, more. Eleventy-billion

The large cables are for my Victron Inverter project

[philh]

how many amps are you running thought that cable, a bazillion?

[richardcoxid]

You can also go to your local wholesale/retail welding equipment dealer and use industrial quality welding cable/terminals.

The dealer will have many gages (reels even) of black welding cable and a selection of terminals. Welding cable is very fine strands which are more flexible than standard automotive battery cable and the insulation is also very flexible and resistant to abrasion/chemicals. As well as a assortment of shrink fit.

Most suppliers will for a small $ amount crimp on the terminals and apply shrink fit etc.

Remember, measure TWICE and CUT ONCE!

Also if you have a scrap of steel approximately 1inch by 2 inch wide by 6 or 8 inches long available, drill a 3/4 to 1 inch diameter hole close to one end (must be large enough for the widest end of the terminal to pass thru) then drill and tap a 1/4 - 20 or a 5/16 - 18 hole 90* from the center line of the big hole. Clamp your tool in your shop vice, prepare one end of the welding cable/terminal place it thru the large hole, tighten the bolt and you have hand dimple clamped the terminal to the cable. (looks better than the “old” chisel/hammer method)

[GaryUT]

I clamp the crimper to the workbench with quick-grip clamps. Put the terminal in the crimper and tighten it just enough to hold the terminal without smashing it. Hold the cable in the terminal and crimp it with your other hand.

Putting the terminal in the crimper first also makes adding a terminal to a cable that's already in place on the trailer.

Gary

[bka0721]

theoldwizard1 wrote:
Those TEMco crimper make very nice crimps, but the cheap hammer/anvil crimp tools are not bad.

Yep, I did the same thing too for my 1860 watt solar system for my truck camper almost a decade ago. Still running strong, too!

When at the race track and we didn't have a crimper, a fall back was using the expansion joint of a sidewalk/curb with a punch and 2 lb sledge. We also used parachute cord for determining the length of the cable by running the cord the route of the cable. Also, used painters tape to draw a line on the tape attached to the cable and lug to ensure the lug to match the orientation for the mounting of the lug to the eventual terminal.

Off topic link removed.

[time2roll]

Very nice to have the right tools.
My crimps look about the same with the hydraulic from HF.

[rickeoni]

Doing the same thing this off season.

[BurbMan]

Let me know if you're taking orders!