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Ev Archive for November 1997
1037 messages, last added Wed Aug 08 18:41:03 2001

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Soldering lugs


  • To: Multiple recipients of list EV <EV@SJSUVM1.SJSU.EDU>
  • Subject: Soldering lugs
  • From: David Roden <roden@ACORN.NET>
  • Date: Wed, 26 Nov 1997 01:34:46 EST
  • In-Reply-To: <9711260250.AA27137@acorn.net>; from "Peter Howell" at Nov 25, 97 8:48 pm
  • Reply-To: Electric Vehicle Discussion List <EV@SJSUVM1.SJSU.EDU>
  • Sender: Electric Vehicle Discussion List <EV@SJSUVM1.SJSU.EDU>

>         Here's my question.  Could one decrease  the limitations of the
> hammer crimper by heating the crimp and wicking in solder?

At the risk of being flamed, I will admit that I have soldered most of
the lugs on my cars for several years now.  In fact, (blush) I don't own
a crimper of any kind.  Nor do I buy commercial lugs.

I cut hunks of copper tubing, dunk the cables in flux, slide the tubing
over the end of the cables, hammer the end flat, and squeeze the part the
wire is in with a vise so they are small in diameter (this is hard to
describe, sorry).  Then I heat them with a torch and dump in gobs of
solder.  Drill the flattened end, and I'm ready for the terminal.

I have never had one overheat -- but then I run 48 to 120 v at 350 to 400
amps, not 192v at 1000 amps.

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   David Roden         THE VIRTUAL PD            roden@acorn.net
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Soldering lugs                                                               R