el cheapo crimp tool
Printed From: The Back Shed
Forum Name: Electronics
Forum Discription: Electrical and electronics discussion.
Printed Date: 20 June 2019 at 1:29am
Software Version: Web Wiz Forums 7.8 - http://www.webwizforums.com
Topic: el cheapo crimp tool
Posted By: Gizmo
Subject: el cheapo crimp tool
Date Posted: 27 January 2016 at 12:57am
Recently I needed to make up some new battery cables using 35mm square cable and lugs. These lugs need to be crimped, and should then be soldered. Soldering isn't enough, its the crimp that retains the cable in the lug if the connection gets hot enough to melt the solder.
I dont have a crimping tool to suit the lugs. I could just squash the lug onto the cable with a vise or hammer, but it looks yuk. A pin or center punch gives a better result, but the lug is still flattened and still looks yuk.
So I made a jig from a piece of hardwood. You could use any hard material, like aluminium or steel. A hole was drilled in the hardwood to be a tight fit over the lug, then I cut out a slot to the hole. The idea of the tight fitting hole is the lug will retain its shape. The pin was made from a piece of rusty 6mm steel rod. Its has a rounded end.
Once the lug and cable are in place, I just hammer the pin to create a nice tight crimp. Then the lug is soldered and finished with some heat shrink.
"If it dont fit, use a bigger hammer."
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Posted By: greybeard
Date Posted: 27 January 2016 at 1:23am
I like the use of a 'rusty' steel rod, nice touch
Great idea though.
Posted By: redrok
Date Posted: 08 March 2016 at 9:14pm
I would not use a "Punch" like tool to do the crimping. My preferred tool is more like a "Wedge". A very dull wedge with a rounded edge of about 1/8th inch. This forms a line lengthwise along the barrel.
|Recently I needed to make up some new battery cables using 35mm square cable and lugs. These lugs need to be crimped, and should then be soldered. Soldering isn't enough, its the crimp that retains the cable in the lug if the connection gets hot enough to melt the solder.
Technically, a good crimp produces a true pressure weld. This is nearly the lowest resistance connection. Then add the solder. The solder adds a gas tight seal against moisture and acid. And yes, will slightly reduce the resistance.
On a side note, if you look in the electrical code solder joints are not allowed unless a functional crimp is done first. Solder joints alone are not allowed.