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Old 12-29-2020, 10:22 PM   #11
trig123
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Default Re: Welding cable and lugs

Thanks for the great information. Tom
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Old 12-30-2020, 10:10 AM   #12
morvolts2
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Default Re: Welding cable and lugs

Quote:
Originally Posted by Z7What View Post
Correct, no soldering is needed. Just crimp and go. With using the #2 terminals with #1 wire and then crimping with the 16Ton crimper i linked above i bet the ring on the terminal would fail before the crimp does.

Heres a close up picture of the terminal after crimping before installing the heat shrink.




Didnt realize there was something that could be damaged. Glad i put a little silicone spray on the wire before sliding through. It wouldnt slide at all without it. With it, the wire slide pretty easy.

Wayne
Z7 can you measure the diameter of the cable you are using for those #2 lugs?
I found a coil of about 100ft. #1 that I stashed in the basement about 40 yrs ago(actually forgot I had it).
Now looking for lugs for it. Measurement is about.350 inches of what I have.
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Old 12-30-2020, 10:29 AM   #13
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Default Re: Welding cable and lugs

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Originally Posted by morvolts2 View Post
Z7 can you measure the diameter of the cable you are using for those #2 lugs?
I found a coil of about 100ft. #1 that I stashed in the basement about 40 yrs ago(actually forgot I had it).
Now looking for lugs for it. Measurement is about.350 inches of what I have.
Not a problem, the only issue is that i wont be able to until Sunday afternoon. Im leaving straight from work today and heading to the hunting camp for the weekend. When i get back ill be sure to measure it for you.

Wayne
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Old 12-30-2020, 12:31 PM   #14
morvolts2
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Default Re: Welding cable and lugs

ok thanks,as you may know welding cable is a different animal when sizing lugs.
Whats odd is some 1/0 lugs are listed for use on #1 welding cable(type W).
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Old 12-30-2020, 01:08 PM   #15
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Default Re: Welding cable and lugs

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Originally Posted by morvolts2 View Post
ok thanks,as you may know welding cable is a different animal when sizing lugs.
Whats odd is some 1/0 lugs are listed for use on #1 welding cable(type W).
I think alot of people think 1/0 and #1 are the same so they list them that way but they are not the same.

Wayne
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Old 12-30-2020, 06:43 PM   #16
morvolts2
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Default Re: Welding cable and lugs

Im looking at the factory specs,not sellers hype.
Compression lugs are a little flexible on squish,but as you know you cant force the wire in.
I looked up a T&B lug inner diameter and it said #2 was .338. My #1 wire is .350.
Yea the wire gauge system is as messed up as the Kings measurement system.
it goes from numbers,in our case,decending order for increase in size#2,#1,then jumps to 1/0,2/0,3/0,4/0,then to circular mils 250mcm,300 mcm,350mcm.
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Old 01-04-2021, 12:15 PM   #17
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Default Re: Welding cable and lugs

Quote:
Originally Posted by morvolts2 View Post
Z7 can you measure the diameter of the cable you are using for those #2 lugs?
I found a coil of about 100ft. #1 that I stashed in the basement about 40 yrs ago(actually forgot I had it).
Now looking for lugs for it. Measurement is about.350 inches of what I have.
The O.D. of the bare wire is right at 5/16" you could probably squeeze it into a terminal with a 1/4" hole though. The wire with insulation still installed is 1/2"

Wayne
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Old 01-04-2021, 10:42 PM   #18
morvolts2
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Default Re: Welding cable and lugs

theres no room in welding cable to force it into a smaller lug.

Did you measure the diameter of the copper only? 5/16" is less than #2 or #1 wire.
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Old 01-05-2021, 08:26 AM   #19
sycraft
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Default Re: Welding cable and lugs

What is the "real" advantage of #1 wire vs #2. I have 2 guage now.
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Old 01-05-2021, 09:34 AM   #20
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Default Re: Welding cable and lugs

You have about a 1% increase in efficiency but no performance increase.

Folks like to show calculations using unrealistic currents and showing how much watts are lost in the cable, all true, but when you compare that "lost" wattage to how much that current means in total wattage being removed from the batteries, it is less than 3% at the most lost in the cables at those current levels.

So it is like taking your car to the shop and they tell you they can do all this work and replace all these wires in your car and it will be 2% more efficient....

Obviously if you have old crunchy cables you should replace them but in my opinion 4ga cables are good for the majority of the installs and 2ga would be better if you consistently pull more than 200amps in hot climates.

The quality of the connections is more important than the difference in gauge beyond 4ga.
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