Re: (ET) New wiring question?

["David Roden" <etpost drmm net>]

I used the existing high power wiring when I installed my Alltrax.  It 
might 
have been better to rewire, but it was kind of chilly in the garage at the 
time. ;-)

I don't recommend soldering high power terminals unless you have no other 
choice.  I've done it, and it's worked OK, but it's not ideal.  The solder 
always wicks up into the wire, stiffening it, and making the connection 
more 
subject to damage from flexing.  

You should never use solder to hold a splice or connection together 
anyway; 
it should already be mechanically strong to begin with.  Solder serves to 
exclude air from splices and stabilize them.  A properly crimped copper 
lug 
doesn't need any soldering. 

Real terminals will always be better and easier to use than those made 
from 
copper tubing.  If nothing else they look better!  But if you're working 
on 
the cheap, tubing is OK.  

Hammer crimpers may be purchased from the EV parts operations such as :

http://www.kta-ev.com/

http://www.electroauto.com/

http://www.evparts.com/

Hex crimpers are nice, but VERY expensive and they take a lot of strength 
to 
work properly.   Some people swear by the homemade ones.  Yes, you can cut 
the cost a lot by making one from cheap Chinese bolt cutters.  (FWIW, the 
original example hacked up by Bill Dube' used an old high quality bolt 
cutter, not a cheapie from Harbor Freight.)  

In my experience, a properly used hammer crimper will make just as good a 
connection as a hex crimper.  It may even do a better job for feebs like 
me 
who have lousy upper body strength.  The only disadvantage is that you 
have 
to have the cables out of the EV or tractor.  Make sure you use a 
substantial hammer; a 20 oz claw hammer isn't going to do it.  I use a 
mini-
sledge.  


David Roden - Akron, Ohio, USA

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