On Sat, 03 Dec 2005 19:07:27 -0500, Larry wrote:

wrote in
:

The only downside is one needs "bellmouthed" crimp lugs as trying to
insert in standard chamfered lugs is a PITA



No, one needs SOLDER CUP lugs...(c; Soldering is NOT a sin! I checked
with a priest. My whole 1973 Mercedes Benz 220D uses solder cup
connectors and has for the past 32 years.

I pulled one apart with fine-stranded #0 welding cable that was soldered
in a cup to see how strong it is. The solder held past when the copper
up in the cable parted...Strong enough? A crimp isn't near as strong.
New solder is much stronger than old LEAD solder.

I or my customers cannot afford the time required to solder 50mm2
cable. I use an Hydraulic crimper which creates an hexagonal crimp.
Strong enough? Yes. I do not hang the battery bank on the cables ;-)
A typical 24V bank requires about 20 crimps a few seconds for each
plus a little more time to heatshrink a coloured sleeve over the shank
and cable.
Also burn back of the insulation can be a problem together with
wicking of the solder up the fine stranded cable.
I have never done a pull test on such a crimp, maybe I could borrow
your Merc to try? ;-)
However I have cut one through and polished the cut face. Looked good
to me!
No its crimp for me every time.
Each to his own!

It is interesting to note that Nigel Calder does not now recommend
welding cable for marine applications, he also suggests that "The
consensus among professionals is that a properly made crimp, done with
the proper tools, is frequently a more reliable termination than
soldering".

Bear in mind that my installations are Inland Waterways.

Richard

Nb "Pound Eater" Parkend G+S