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Old 3rd May 2013, 21:02   #16
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Default Re: DIY: Battery Jump Leads for Jeeps & Offroaders

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How did you crimp the cable sir?
If I'm not mistaken, (acid) soldered.

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Sutripta
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Old 3rd May 2013, 21:28   #17
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Default Re: DIY: Battery Jump Leads for Jeeps & Offroaders

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How did you crimp the cable sir?
Wrong question, remove the Sir

Ok, I did this using hammer, chisel & bit of bench vice.

These lugs have a seam. If you want to hand crimp them at home, without the use of the crimping tool, try this. (assuming you have selected a proper size of lug for the wire gauge)

# Remove insulation, approx 1.5 times of the lug round portion length.

# Insert the bare cable into the Lug.

# Start poking the chisel on the seam of the Lug.

# It will first take some impact & then the seam will open

# As soon as it opens, press one side fully with hammer on the cable & then take this to the vice & compress, so that another side slides over the bent one. remove from vice & perfect the job with bit of hammering .

This way a little space is left in the lug which holds the cable more tightly & then ready for solder. Although where no soldering is available, with little practice, you can give a taper (funnel) shape to the rounding . So that the cable does not pull out of the hand crimped lug.

Attaching the image, it works something like this.

DIY: Battery Jump Leads for Jeeps & Offroaders-crimp.png

Sudarshan

Last edited by Sudarshan : 3rd May 2013 at 21:30.
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Old 4th May 2013, 13:46   #18
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Default Re: DIY: Battery Jump Leads for Jeeps & Offroaders

Thanks I do know how to use a crimping tool!!

Though i agree to your method, i would prefer a crimping tool to ensure the bite into the cable is perfect.
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Old 6th May 2013, 00:57   #19
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Default Re: DIY: Battery Jump Leads for Jeeps & Offroaders

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There are tables available on net to calculate cable size .

Sudarshan
Good job done. Thanks for posting with the pictures. Can you please send me the links from where I can get the type of cables and the size to be used?
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Old 30th May 2013, 09:32   #20
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Smile Re: DIY: Battery Jump Leads for Jeeps & Offroaders

Quote:
Originally Posted by headers View Post
Thanks I do know how to use a crimping tool!!

Though i agree to your method, i would prefer a crimping tool to ensure the bite into the cable is perfect.
However I will strongly suggest to solder them also.

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Originally Posted by byomjeet View Post
Good job done. Thanks for posting with the pictures. Can you please send me the links from where I can get the type of cables and the size to be used?
Search as cable size calculator on Google, & also read the complete thread carefully (all posts). For Jeeps & equivalent engines with a 70/90 Amp/hr battery at hand, a 50 sq mm copper cable up to 2 mtrs length is OK, IMHO.

No need for further research, dont make it too complicated

Sudarshan
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