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Building my own batterty cables

deltabravo
Nomad
Nomad
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
2009 Silverado 3500HD Dually, D/A, CCLB 4x4 (bought new 8/30/09)
2018 Arctic Fox 992 with an Onan 2500i "quiet" model generator
18 REPLIES 18

deltabravo
Nomad
Nomad
Here's a little more detail on the crimpers: Unboxing video / intro
2009 Silverado 3500HD Dually, D/A, CCLB 4x4 (bought new 8/30/09)
2018 Arctic Fox 992 with an Onan 2500i "quiet" model generator

deltabravo
Nomad
Nomad
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.
2009 Silverado 3500HD Dually, D/A, CCLB 4x4 (bought new 8/30/09)
2018 Arctic Fox 992 with an Onan 2500i "quiet" model generator

time2roll
Nomad
Nomad
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_
Explorer II
Explorer II
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.
Tim & Sue
Hershey (Sheltie)
2005 F150 4x4 Lariat 5.4L 3.73 Please buy a Hybrid...I need your gas for my 35.7 gallon tank!
2000 Nash 19B...comfortably pimped with a real Queen Size Bed

Super_Dave
Explorer
Explorer
I go to Amazon and buy cables already made up in 1' increments.
Truck: 2006 Dodge 3500 Dually
Rig: 2018 Big Country 3155 RLK
Boat: 21' North River Seahawk

deltabravo
Nomad
Nomad
duplicate
2009 Silverado 3500HD Dually, D/A, CCLB 4x4 (bought new 8/30/09)
2018 Arctic Fox 992 with an Onan 2500i "quiet" model generator

deltabravo
Nomad
Nomad
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
2009 Silverado 3500HD Dually, D/A, CCLB 4x4 (bought new 8/30/09)
2018 Arctic Fox 992 with an Onan 2500i "quiet" model generator

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

richardcoxid
Explorer
Explorer
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 โ€œoldโ€ chisel/hammer method)
2017 GMC Denali 3500 4x4 Duramax
2019 Outdoor RV (ORV) Timber Ridge 24RKS

GaryUT
Explorer II
Explorer II
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
2019 Keystone Laredo 255SRL
2009 GMC Sierra 2500 4x4 Crew cab short bed

bka0721
Explorer II
Explorer II
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.
08 F550-4X4-CC-6.4L Dsl-206"WB GVWR17,950#
09 Lance 1191
1,560wSolar~10-6vGC2-1,160AmpH~Tri-Star-Two(2)60/MPPT~Xantrex 2000W
300wSolar~2-6vAGM-300AmpH~Tri-Star45/MPPT~Xantrex 1500W
16 BMW R1200GSW Adventure
16 KTM 500 EXC
06 Honda CRF450X
09 Haulmark Trlr

time2roll
Nomad
Nomad
Very nice to have the right tools.
My crimps look about the same with the hydraulic from HF.

rickeoni
Explorer
Explorer
Doing the same thing this off season.


2008 F450
2007 Adventurer 85WS
2012 Haulmark "The Garage"
2016 Outdoors RV Glacier Peak 26 RKS

BurbMan
Explorer II
Explorer II
Let me know if you're taking orders!