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Michael's RV-10 Build Log
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Date:  6-13-2008
Number of Hours:  1.75
Manual Reference:  
Brief Description:  Made some battery cables

Spent some time this morning fabricating up battery cables. I spent some time looking around the net for a DIY way to crimp the ends on the cables as the real crimpers are rather expensive. The two ways that seemed the most promising were using a bolt cutter with a 12mm socket cut in half and welded into the jaws as a crimper and the other was using a modified bolt splitter. I opted to try the bolt spliiter first so I ground the point down to a flatter profile and made my first attempt. It turned out useable but the angle on the bolt splitter makes it difficult to control. After a couple ends I learned that I could flatten the end in the vise firs and then use the splitter to really put a squeeze on it in the middle like it should have. Turned out real nice after that. The important thing besides a good mechanical bond is to try and get the crimp gas tight to prevent any corrosion. I'm using #2 welding cable which uses many more fine strands than regular cables. This makes it much more flexible and the strands "flow" better in the crimp. I did try soldering one of the connections that act as a simple strap acroos the battery grounds but I'm just not a fan of that. Sure it will give you an excellent electrical connection but crimping will do the same thing if done right and give you a much better mechanical bond. Even though the ends are tin plated copper, I still used an antioxidant paste on the wire before I crimped it for an extra measure against any corrosion.
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The bolt splitter and my first crimp

The bolt splitter and my first crimp

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Ground strap

Ground strap

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Battery compartment with most cables

Battery compartment with most cables

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