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4 awg and Larger, Best Method to Attach Lugs
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<blockquote data-quote="HardofWhoring" data-source="post: 8829007" data-attributes="member: 674149"><p>Have to start with a clean cut. Measure the depth of the lug, and use a boxcutter to remove the sheath just shy of the length, (hold the cutter still, and turn the wire on it around once, then up through). Some lugs have an angle inside that comes to the point. If it does, you can cut the wire at a slight angle; then inserting it all in the lug is pretty easy by just spinning it. If the lug is more flat at the end, then a straight cut on the wire. Welding wire is pretty easy to get in, with a clean cut and twist it around because its just packed tighter. With flex wire, I will use a really small zip tie over the exposed wire. Make the zip tie tight over the end (but not as tight as possible), with just enough room to fit the lug over, and slide them both down. When the lug is seated over the wire, you cut the zip tie off at the "head/connector". Don't try to go all the way through, just enough to break its strength so you don't cut the wire.</p><p></p><p>I've tried hammer crimpers, and I thought they were worthless. Hydraulic crimpers are $20 on Amazon. Smaller than 8awg I only solder. 4awg and larger I only use the crimpers. I just don't see how you're planning on getting solder in there, unless you are going around the end lip of the lug. I crimp, move it slightly and crimp again along the lines, so the entire lug is crimped where there is wire inserted.</p><p></p><p>A little dielectric grease and a heat shrink tubing over the crimped portion.</p><p></p><p>If both ends are getting lugs, then after the first lug, seat the second lug on the wire, install it close, and adjust the angle of the lug before crimping it.</p></blockquote><p></p>
[QUOTE="HardofWhoring, post: 8829007, member: 674149"] Have to start with a clean cut. Measure the depth of the lug, and use a boxcutter to remove the sheath just shy of the length, (hold the cutter still, and turn the wire on it around once, then up through). Some lugs have an angle inside that comes to the point. If it does, you can cut the wire at a slight angle; then inserting it all in the lug is pretty easy by just spinning it. If the lug is more flat at the end, then a straight cut on the wire. Welding wire is pretty easy to get in, with a clean cut and twist it around because its just packed tighter. With flex wire, I will use a really small zip tie over the exposed wire. Make the zip tie tight over the end (but not as tight as possible), with just enough room to fit the lug over, and slide them both down. When the lug is seated over the wire, you cut the zip tie off at the "head/connector". Don't try to go all the way through, just enough to break its strength so you don't cut the wire. I've tried hammer crimpers, and I thought they were worthless. Hydraulic crimpers are $20 on Amazon. Smaller than 8awg I only solder. 4awg and larger I only use the crimpers. I just don't see how you're planning on getting solder in there, unless you are going around the end lip of the lug. I crimp, move it slightly and crimp again along the lines, so the entire lug is crimped where there is wire inserted. A little dielectric grease and a heat shrink tubing over the crimped portion. If both ends are getting lugs, then after the first lug, seat the second lug on the wire, install it close, and adjust the angle of the lug before crimping it. [/QUOTE]
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4 awg and Larger, Best Method to Attach Lugs
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