Tech Updates
BUILDING A CUSTOM BATTERY CABLE
P
hillips Industries has
released these tips for
creating a custom battery cable when a pre-assembled cable just won't do.
Battery cables can be
built three ways, by crimping, crimping and using heat
shrink tubing and soldering
terminals and slugs and then
using heat shrink tubing.
Phillips says crimping is
the quickest custom assembly
method but has the highest
risk of corrosion, while the
second and third methods
take long to do but dramatically reduce corrosion risks.
The company says the
second option, crimping and
heat shrink tubing, is the
most common method.
In its October edition
of Qwik Tech Tips, Phillips
Industries lays out the steps
for building a cable using
crimping and heat shrink
tubing.
Confirm the length of
battery cable needed.
Strip 7/8 in. of the jacketing from the end of the
battery cable. Battery terminal barrels require approximately ¾ in. (Figure 1)
Slip 1.5 in. of the heat
shrink tubing over the
end of the battery cable and
slide it out of the way. Insert
the bare battery cable wire
1
2
3
into the barrel of the battery
terminal. (Figure 2)
Set the dies of the
crimping tool for the
size and color code battery terminal you are using.
Crimp tool die codes and
sizes are printed on every
battery terminal. (Figure 3)
All cast copper battery
terminals are designed
for two crimps (four crimps
on flag terminals). Make the
first crimp closest to the barrel opening and the second
crimp furthest away from the
opening. (Figure 4)
Slide the shrink tubing
over the terminal with
the center of the tubing
4
5
6
aligned with the end of
the barrel. Use a heat gun
or torch to shrink tubing
down over the connection.
(Important: Be careful to
heat the shrink tubing evenly
all the way around. Shrink
tubing can melt if it gets too
hot.) (Figure 5)
For more information on
building a custom battery
cable, visit the Qwik Tech
Tips website.
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