Phillips Industries Thursday released its July issue of Qwik Tech Tips. This month’s issue shows technicians and vehicle owners how to build a custom battery cable for a commercial vehicle application.
Phillips Industries states in this month’s issue that battery cables can be purchased pre-assembled or they can be custom built to accommodate differing lengths and stud sizes. But the company also notes, pre-assembled battery cables might not always reach the battery terminals or may create disorganization if cables are too long.
“Custom building your own battery cables can easily be your best option, especially when you may be working with multiple vehicles that don’t have the same specifications,” the company says.
Phillips Industries says there are three different ways to build a battery cable. The company describes them as follows:
- Crimp: This only requires crimping the terminals and or lugs. While this method is quick, it’s not effective at keeping corrosion from entering the cable.
- Crimp and Heat Shrink Tubing: This is the most common method used. The terminal/lug is crimped, and then sealed with heat shrink tubing. The heat shrink tubing helps to prevent corrosion.
- Solder Terminals/Solder Slugs and Heat Shrink Tubing: This method offers a superior connection. Heat shrink tubing offers corrosion protection. (Note: Most crimp type terminals are designed for crimp or solder.)
This month’s Qwik Tech Tips also offers six steps for technicians and do-it-yourselfers to follow to make their own battery cables using the popular crimp and heat shrink method.
- Strip 7/8 in. (22-25mm) of the jacketing from the end of the battery cable. Battery terminal barrels require approximately ¾ in. (18-20mm). See Fig. 1.
- Slip 1.5 in. (38mm) of the heat shrink tubing over the end of the battery cable and slide it out of the way. Insert the bare battery cable wire into the barrel of the battery terminal. See Fig. 2
- Set the dies of the crimping tool for the size and color code battery terminal you are using. Crimp tool die codes and sizes are printed on every battery terminal. See Fig. 3
- All cast copper battery terminals are designed for two crimps (four crimps on flag terminals). Make the first crimp closest to the barrel opening and the second crimp furthest away from the opening. See Fig. 4
- Slide the shrink tubing over the terminal with the center of the tubing aligned with the end of the barrel. Use a heat gun or torch to shrink tubing down over the connection. (Important: Be careful to heat the shrink tubing evenly all the way around. Shrink tubing can melt if it gets too hot.) See Fig. 5.
To read more from Phillips on this method, and other tips when it comes to battery cable assembly, please CLICK HERE.
