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Battery lug crimping tool for #4 to 4/0 heavy duty (mega) lugs

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  • Battery lug crimping tool for #4 to 4/0 heavy duty (mega) lugs

    OK folks - this could go in the tool list section, but after searching I was not finding much on the tools needed to properly make my own cables.
    I use this article for reference https://marinehowto.com/making-your-own-battery-cables/

    The crimper I think I should get is https://www.amazon.com/FTZ-Correct-C.../dp/B01CRZ465K recommended in the article. This is a swaging type crimper
    Others I have found mentioned
    https://temcoindustrial.com/temco-th...g-crimper.html this is an indent type crimper.
    and
    https://www.amazon.com/dp/B07X2WS3L4...4-1c76e7d78a95 videos make this look easy (several brands)

    Then there is this, but as it is metric I am not sure it goes to 4/0
    https://www.amazon.com/dp/B00HJXG3KM...ogi&th=1&psc=1

    Recommended lug source
    https://www.elecdirect.com/lug-compr...ed-copper-lugs

    So is one crimping method better than the others?

    I do see information and products for a soldered connection - but I will pass on that'

    Am I overthinking this? And given the tool costs one option would be to get everything , measure and order pre-made, but who uses welding cable in their pre-made cables along with the heavier duty lugs?

    Thanks folks
    Keith
    2018 Reflection 150 Series 220RK 5th whee, Star White 2022 F350 King Ranch CC Long bed (HAL) (CCC 4062lbs), B&W 25K OEM Companion,. SteadyFast system, Trailer reverse lights, rear receiver spare tire holder, storage tube, sumo springs, Victron MultiPlus 12/120/3000, Solar, Custom 6K axles upgrade, and other modifications.

  • #2
    Keith

    I purchased the Temco one that you have listed , Cate&Rob recommended this. When I relocated my battery switch it worked well to make the stock cables shorter.

    ​​​​​​​Brian
    Brian & Michelle
    2018 Reflection 29RS
    2022 Chevy 3500HD

    Comment


    • #3
      I guess that I would ask your intentions. Is it to have another tool (that) in most cases you may only use it (maybe) once in your life? Or are you planning on doing a lot of modifications in the future? If you purchase one that has limited sizes it will make it more costly when you find it's just out of reach for smaller needs.
      As a former Mechanical Contractor I would see it both ways, one in which an employee swore he needed a tool to get a job done, then never used it again. The other is, you would have that tool hopefully forever when the need arises.
      If only once or maybe twice, and you have a good old fashion auto parts store (not like the modern franchised box store type) nearby they will can make up cabling for you. I would, at all costs (or lack of it) stay away from the hammer type unless you use it in a vise! Hammering, you have no control on the pressure exerted on the tool.
      I cant count the amount of times (in a hurry) I personally have done crimping on my own equipment; mowers, tractors, trucks, etc. and used a vise with a nut or bolt as my crimping tool and years later look at it & shake my head at myself!
      And most important, use strain relief! And, for what little it may cost you, use dielectric grease on everything! You only need a thin layer for a piece of mind.
      Gary & Sheryl
      2017 Reflection 29RS
      2020 F250 7.3 Gaszilla

      Comment


      • #4
        Originally posted by GeoTech View Post
        I guess that I would ask your intentions. Is it to have another tool (that) in most cases you may only use it (maybe) once in your life? Or are you planning on doing a lot of modifications in the future? If you purchase one that has limited sizes it will make it more costly when you find it's just out of reach for smaller needs.
        As a former Mechanical Contractor I would see it both ways, one in which an employee swore he needed a tool to get a job done, then never used it again. The other is, you would have that tool hopefully forever when the need arises.
        If only once or maybe twice, and you have a good old fashion auto parts store (not like the modern franchised box store type) nearby they will can make up cabling for you. I would, at all costs (or lack of it) stay away from the hammer type unless you use it in a vise! Hammering, you have no control on the pressure exerted on the tool.
        I cant count the amount of times (in a hurry) I personally have done crimping on my own equipment; mowers, tractors, trucks, etc. and used a vise with a nut or bolt as my crimping tool and years later look at it & shake my head at myself!
        And most important, use strain relief! And, for what little it may cost you, use dielectric grease on everything! You only need a thin layer for a piece of mind.
        Just a quick hijack of Keith's thread to welcome you to the forum, Gary & Sheryl (noted that was your first post). Always puts a grin on my face when a first post is informative/helpful!

        If you haven't seen it yet, there's a Welcome Letter to New Members https://gdrvowners.com/forum/main-fo...to-new-members

        Great to have you two here--look forward to future posts.

        Howard
        Forum moderators are not GD employees--we are volunteers and owners presumably just like yourself. Unless specifically mentioned otherwise, we have nothing to gain should you choose to purchase a product or engage a service we discuss on this forum.

        2017 Ford F-350 DRW, '19 315RLTSPlus

        Comment


        • #5
          Originally posted by Yoda View Post
          OK folks - this could go in the tool list section, but after searching I was not finding much on the tools needed to properly make my own cables.
          I use this article for reference https://marinehowto.com/making-your-own-battery-cables/

          The crimper I think I should get is https://www.amazon.com/FTZ-Correct-C.../dp/B01CRZ465K recommended in the article. This is a swaging type crimper
          Others I have found mentioned
          https://temcoindustrial.com/temco-th...g-crimper.html this is an indent type crimper.
          and
          https://www.amazon.com/dp/B07X2WS3L4...4-1c76e7d78a95 videos make this look easy (several brands)

          Then there is this, but as it is metric I am not sure it goes to 4/0
          https://www.amazon.com/dp/B00HJXG3KM...ogi&th=1&psc=1

          Recommended lug source
          https://www.elecdirect.com/lug-compr...ed-copper-lugs

          So is one crimping method better than the others?

          I do see information and products for a soldered connection - but I will pass on that'

          Am I overthinking this? And given the tool costs one option would be to get everything , measure and order pre-made, but who uses welding cable in their pre-made cables along with the heavier duty lugs?

          Thanks folks
          Keith
          You may want to see if you can 'rent' for free a crimper from a chain parts store. They have a good number of auto tools that can be borrowed with a deposit that is refunded when returned

          Why are you steering clear of the solder or sweating method? I have always felt this would be the best for reducing corrosion and superior connectivity. An did the only told you need is a good flame. I could be wrong.
          Mike & Lisa
          Central Florida
          2021 Imagine 2970RL
          1996 Chevy K3500 Crew SRW 7.4L Gas

          Comment


          • #6
            Originally posted by Yoda View Post
            OK folks - this could go in the tool list section, but after searching I was not finding much on the tools needed to properly make my own cables.
            From my inverter presentation PDF (and yes, it's the same crimper I believe Rob suggested).

            Note the suggested clamping method shown in the picture.


            Click image for larger version  Name:	Slide21.JPG Views:	0 Size:	141.9 KB ID:	39306


            Click image for larger version  Name:	Slide22.JPG Views:	0 Size:	94.3 KB ID:	39305
            Last edited by howson; 01-03-2021, 08:43 AM.
            Forum moderators are not GD employees--we are volunteers and owners presumably just like yourself. Unless specifically mentioned otherwise, we have nothing to gain should you choose to purchase a product or engage a service we discuss on this forum.

            2017 Ford F-350 DRW, '19 315RLTSPlus

            Comment


            • #7
              Originally posted by GeoTech View Post
              And, for what little it may cost you, use dielectric grease on everything! You only need a thin layer for a piece of mind.
              This is the first mention I have heard of using dielectric grease. I'd be interested in other peoples thoughts and experiences. Do you use it when assembling the lugs? I plan to use the tinned copper lugs.
              John & Karen, RV Newbies
              2020 Relection 150, 260RD
              GMC Sierra Denali 2500

              Comment


              • #8
                I believe this reference was first posted by gbkims : https://marinehowto.com/marine-wire-termination/

                Another great resource: https://www.victronenergy.com/blog/2...ing-unlimited/

                For those who really want to geek out over the details (Keith!) the Electrical Connections for Power Circuits (US Gov doc) is another resource: https://www.usbr.gov/power/data/fist/fist3_3/vol3-3.pdf IMHO it's a bit of overkill for the level of work we're doing on our RVs, but it's available nonetheless.

                Again--let me emphasize credit for these references goes to Gene ( gbkims ), aka "Gandalf". All I did was save the references he's mentioned in my library for ease of reference.

                I'm going to add all of these in one post (along with Keith's) in one Reference Material post at some point.
                Forum moderators are not GD employees--we are volunteers and owners presumably just like yourself. Unless specifically mentioned otherwise, we have nothing to gain should you choose to purchase a product or engage a service we discuss on this forum.

                2017 Ford F-350 DRW, '19 315RLTSPlus

                Comment


                • #9
                  I bought this one:
                  https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

                  Worked great for my re-wiring project and does 4/0 lugs. I chose to buy the tools and spare wire and lugs not only so I could cut each wire to length but also because I know this won't be the last time I rewire an RV. Plus I have the tools and spare parts I need in case somebody else ever needs help.
                  Brian & Kellie
                  2020 Grand Design Solitude 310GK-R, FBP, MORryde IS, 1,460w solar and 540ah BBGC3
                  2020 Ford F-350 Platinum SRW PSD Tremor, 60g TF fuel tank, Hensley BD3-F air bag hitch

                  Previous setups:
                  2019 Grand Design Solitude 373FB-R, 2019 Ford F-350 Platinum DRW Powerstroke, Hensley BD5 air bag hitch
                  2016 Grand Design Reflection 318RST, 2016 GMC 3500 Denali SRW Duramax, Hensley BD3 air bag hitch

                  Comment


                  • #10
                    Originally posted by howson View Post
                    Note the suggested clamping method shown in the picture.
                    It is interesting that the lug crimpers that I have been using for over 20 years (through many boat projects for myself and others) have sparked such discussion. I have often thought that my crimpers should have a flat on the back to allow then to sit upright on a surface just like Howard shows in his picture. (Mine don't have that "improvement".) I can certainly see the value of the smaller hydraulic crimper in a case with interchangeable dies . . . but nothing can be simpler than the screw adjusted die in the ones that I use.

                    WRT using dielectric grease . . . I have always used this for electric connections that are designed to come apart. Connectors, bulb sockets, etc. I have never used it in a "permanent" crimped connection, but I don't suppose this would cause any problems as long as the crimp is tight enough to retain the wire even with the dielectric grease lubrication (which it should be anyway). I have always used heat shrink insulation over positive lug to wire connections. I suspect that the heat from doing this would melt away the dielectric grease.

                    Rob

                    Cate & Rob
                    (with Border Collies Molly & Angel + Kitties Hazel & Elsie)
                    2015 Reflection 303RLS
                    2022 F350 Diesel CC SB SRW Lariat
                    Bayham, Ontario, Canada

                    Comment


                    • #11
                      I also purchased the TEMCO crimper and used it for all my larger connections. It worked very well for me, and the connections have held up for two years now with no failures. Note: My battery cables are 2/0 AWG welding cable with heat shrink applied.

                      Click image for larger version

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                      Jim
                      Jim and Ginnie
                      2024 Solitude 310GK
                      GDRV Technical Forum Moderator
                      GDRV Rally Support Coordinator

                      Comment


                      • #12
                        I bought the Temco crimper you referenced in your OP. It worked fine on normal lugs, but I couldn't even dent a megalug with it. I bought the SG Tool Aid, which does a perimeter crimp, but it was so much easier to use. It crimped the megalug just fine.
                        John & Karen, RV Newbies
                        2020 Relection 150, 260RD
                        GMC Sierra Denali 2500

                        Comment

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