Battery cable - positive side - terminal broke - Page 4 - Diesel Forum - TheDieselStop.com
Power Stroke Excursions Technical discussion of the Ford Excursion SUV with the Power Stroke diesel.

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post #46 of 56 (permalink) Old 01-07-2018, 01:01 PM
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I finally picked up some various sized copper ring terminal lugs to fix my crappy corroded stock 6.0 positive cable ends. I need to ensure that i've got the proper fitment between the cable and the lug and i need to determine the proper die size to crump the lugs with my new hydraulic crimper.

Here is my problem, I've taken some 6 AWG Lugs and prepared some 6 AWG Cable for the new lug. (I realize that this is too small for battery cable but wanted to practice on cable that I've got lying around the garage.) The issue is that it seems like the 6 AWG lug is too big for the 6 AWG cable after the insulation has been stripped from the wire. I'm sure I could crimp it if I used a much smaller die but it just doesn't seem right. I would assume that the bare wire shoud be snug in the lug before the lug gets crimped. To accomplish this I'd actually have to use an 8 AWG lug for the 6 AWG wire.

Again, I'm only using the smaller wire for practice but assume that the same might be true for bigger wire (i.e. go smaller on the lug to ensure snug fit before crimping)

Can anyone with experience please shed some light on this?

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post #47 of 56 (permalink) Old 01-07-2018, 04:10 PM
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My experience has been that the terminal sizing is variable. Maybe if I wasn't so cheap (ie. bought better terminals) they would be more consistent. I just use whichever die is close. This isn't brain surgery and even my worst crimps are significantly better than a lot of what I see in production situations.

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post #48 of 56 (permalink) Old 01-08-2018, 08:22 AM
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My experience has been that the terminal sizing is variable. Maybe if I wasn't so cheap (ie. bought better terminals) they would be more consistent. I just use whichever die is close. This isn't brain surgery and even my worst crimps are significantly better than a lot of what I see in production situations.
Understood. I'm frugal as well and copper terminal lugs are expensive which is why I want to make sure I've got my plan in place before I go crimping and then having to discard bad-crimped lugs.

I actually tried one yesterday (6 AWG Cable with 6 AWG lug) using recommended 16mm die and it did a good job. It seemed like the lug was too big but it worked ok. I may try an 8 AWG lug to see if it fits better, pre-crimp.

I know this is a relatively boring subject but good connections are important.
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post #49 of 56 (permalink) Old 01-08-2018, 11:58 AM
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If you're doing practice crimps anyway then cut one open to see how well you're doing. I've never cut into one but I've been told that a properly crimped join will fuse the metal together.

2006 F250 6.0 4x4
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post #50 of 56 (permalink) Old 01-08-2018, 12:21 PM
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Crimping does not fuse metal. (Soldering, brazing, & welding do.) But crimps CAN be cut open for inspection & diagnosis.


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post #51 of 56 (permalink) Old 01-08-2018, 12:23 PM
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That would take a lot of force. Lol

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post #52 of 56 (permalink) Old 01-08-2018, 12:26 PM
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I saw a really-interesting show a few years ago about explosive-welding sheets of dissimilar metals together to make hybrid metal laminates.


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post #53 of 56 (permalink) Old 01-08-2018, 02:44 PM
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I saw that. I think it was on how it's made.

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post #54 of 56 (permalink) Old 01-08-2018, 10:52 PM
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The one I saw was probably an hour-long piece, showing the prep, the abandoned mine where they blast, and the stuff they make from the laminates, like bomb shelters for the rich & governmental. It couldn't have been a 10-min segment in How It's Made. Maybe Modern Marvels, or Engineering the Impossible. I can't find it on IMDb, though.


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post #55 of 56 (permalink) Old 01-11-2018, 08:45 PM
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Try season 13 episode 12 of modern marvels.

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post #56 of 56 (permalink) Old 01-14-2018, 10:34 AM
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Try season 13 episode 12 of modern marvels.

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