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Safari Helicopter Construction
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Date:  10-7-2007
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Making battery cables

I spent most of the day measuring, cutting, soldering and heat shrinking the six large diameter power and ground cables for the electrical system.

I found it necessary to gently bend some of the terminals prior to soldering so they would fit where they need to go. I heated them with the propane torch after clamping in a vice before bending.

I compared resistance readings of the cable before and after soldering the terminals on the ends to ensure they had good electrical continuity.The large, thick walled heat shrink tube has a 3 to 1 shrink ratio and is adhesive lined to help seal out moisture. I had purchased a cable crimper earlier to fasten the terminal with, but I believe the solder method makes a better connection.
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Extra large heat shrink tubing

Extra large heat shrink tubing

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Filling the cup with solder

Filling the cup with solder

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The finished article

The finished article

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