Crimping Amp 4 AWG cable lugs [SOLVED]

So my amp came with a great power cable kit from tech12volts, Sosche brand. Also came with little cable lugs for the ends.

Turn out those are rather soft, can't just smack them with a hammer, I tried that. They don't stay tight. Trying to melt some solder in there didn't turn out well either - my puny little soldering iron wouldn't even get it started and using a MAPP gas torch to head the lug/cable didn't seem to work either. The solder did melt but only formed a puddle at the end of the cable rather than wicking into the wire.

Going to cave in and get the real tool, a HF hydraulic crimper: Hopefully I can still salvage the lugs, will try to open them again with a punch.

 

Look at the package for the wire, is it OFC (oxygen free copper) or CCA (copper clad aluminum)?

I really like soldering them, you should not have a problem with getting filling up the lug with solder. Watch a couple youtube videos on it. A soldering iron wont cut it, i fluxed the inside of the lug, used a propane torch to slowly heat the lug until solder would flow in, and kept going until it was damn near full.

 

I use a slightly cheaper version from Amazon. I think any of them in the yellow case are from the same overseas supplier.

$46 Yescom 10 Ton Hydraulic Wire Crimper Battery Cable Lug Terminal Crimping Tool with 9 Dies

https://www.amazon.com/Yescom-Hydra...B00KS4R3PI/ref=dp_prsubs_1?pd_rd_i=B00KS4R3PI


Works well. Also here's the die size chart.

 

The terminals that came with my kit had a split in the top. I used channel locks to push one side under the other, crimped side to side, then top to bottom, then repeated. Seemed to do the trick for me, but I’m sure it could have been done better.

 

Since I knew I wouldn't use it much, I went cheap on a crimper.
This one has worked well for me, used with 4 and 0 ga terminals

$21 TEMCo Hammer Lug Crimper Tool - Crimps 8 AWG to 4/0 Battery & Welding Cables (Workbench-Mountable)

TEMCo Hammer Lug Crimper Tool 5 Year Warranty - Battery Terminal Crimper - Amazon.com

$9 SELTERM 10pcs 4 AWG - 3/8" Stud - Battery Lugs, Heavy Duty Wire Lugs, Ring Terminals, Battery Cable Ends,4 Guage Terminals, UL Bare Copper Eyelets Electrical Battery Terminal Connectors

Amazon.com : SELTERM 4 AWG 3/8" Stud (10 pcs.) UL Heavy Duty Wire Lugs, Battery Cable Ends, Bare Copper Eyelets, Tubular Ring Terminal Connectors [B35] : Sports & Outdoors

$11 SELTERM 10pcs 1 AWG - 3/8" Stud - Battery Lugs, Heavy Duty Wire Lugs, Ring Terminals, Battery Cable Ends,1 Gauge Terminals, UL Bare Copper Eyelets Electrical Battery Terminal Connectors

Amazon.com : SELTERM 4 AWG 3/8" Stud (10 pcs.) UL Heavy Duty Wire Lugs, Battery Cable Ends, Bare Copper Eyelets, Tubular Ring Terminal Connectors [B35] : Sports & Outdoors

 

I have a hammer crimper too... but I sure would love the convenience of crimping at the truck with a hydraulic assist vs at the bench!

 

I've seen that one online many time. However, I've gone from "I'll never need a crimper" to being on my 3rd or 4th project now. The HF crimper comes with a ton of dies.

 

Get the HF crimper, it works really well. Beats trying to smack the terminal or the crimper above with a hammer, especially when it’s on the vehicle. I’ve tried all of the above and it’s an exercise in futility. The hydraulic crimper is so nice to use after all that frustration.

 

So the "4 AWG" die that came with the tool looks minuscule compared to the supplied lug. What am I missing?

The Lug is also the split kind, can't see this ending well. Will just end up with a flat, squished cable end with little bumps in the middle.

 

That's a good point.
I've never had to use it on wires in the vehicle.
Just on new installations.

 

It ended up working very well. I started with the 0 AWG dies, then 2 AWG, finished with 4 AWG. I had fluxed per earlier recommendation. Finally heated up the end with MAPP gas and ran some solder in there. Should be on there for life!

 

+1 for the Temco hammer smash one. Flawless for me.

 

I used this one.

$262 Thomas & Betts TBM45S Crimping Tool with Shure Stake Mechanism for 8 through 2 Copper and 10 through 6 Aluminum Lugs

https://www.amazon.com/Thomas-Betts-TBM45S-Crimping-Mechanism/dp/B007QS8VQO

 

So you crimped and soldered?

 

Yeah it works fine on the bench but imagine me trying to figure out a safe way to use it on a car lol

 

Yes indeed. My "vice grip crimp" wasn't very strong, after I used the hydraulic crimper it's rock solid. Added a little solder for good measure.

 

Yep, hydraulic crimpers are the way to go. We calibrate thousands of them at work every year. Widely used and depending on use require periodic calibration.

 

That's a very good crimper BTW!

 

Especially since I borrowed them from work!

 

Temco

 

A crimp is only as good as the tool and material can provide. The better the tool, the better the crimp. I have used this amphenol/king tool for just about everything for almost 20 years... Never a bad crimp.

https://www.mouser.com/Search/Refine?Keyword=227-944

Yes I have many dies and yes they all cost hundreds of dollars each. But you don't need a new tool everytime the connector type changes, you just buy the die and you're good to go.