Offthewall
Solar Enthusiast
Try 1 + die and one 4awg
crimping lugs causing wings. should i redo?
- Thread starter rillweed
- Start date
bestconcreteblock
Solar Enthusiast
- Joined
- Dec 5, 2022
- Messages
- 136
Definitely is. Nothing wrong with this in my opinion. You are just continuing the crimp.
I have had this before. I think you are using thick walled marine grade lugs and the dies obviously do not fit. You can do it a million times and it will keep happening. I think you should be fine trimming those pieces off, but I would try to get a different crimper. A hammer crimper may not be as fancy, but it will give a solid crimp.
You could also use the crimper at a 90 degree rotation after the first crimp to push all the excess back into the crimp. Again, not ideal, but shouldnt hurt it.
You could also crimp until it is about to push out the sides, stop, then cut the crimp in half to ensure there is a cold weld. It would cost a whole lug, but if you can verify that it does not need the dies entirely flush to get a full crimp, youll be set.
You could also crimp until it is about to push out the sides, stop, then cut the crimp in half to ensure there is a cold weld. It would cost a whole lug, but if you can verify that it does not need the dies entirely flush to get a full crimp, youll be set.
rillweed
New Member
temco makes no mention of them having thicker walls but they are considered marine grade and are tinned. Example product page https://temcoindustrial.com/tinned-copper-ring-terminal-1-awg-1-2-hole-25-pack/?searchid=83581
rillweed
New Member
Here is one more test. First crimp is using the 2AWG (doesn't hold wire), then 4AWG+ (doesn't hold wire), then 4AWG. I noticed the 4AWG was starting to form wings, so I stopped and rotated it at that point. In the cross section picture you can see where the wing was rotated and compressed. Is this acceptable?
DPC
Canada, Great already
Your lugs are not correct for your wire.
I see a flare on one.
Made for a fine strand cable.
Might be the wrong lug for the cable.
This is why I like to use a pin crimper.
I know its no longer code compliant but I can feel my way through a problem.
Last two crimps look like they are good I would use them.
I see a flare on one.
Made for a fine strand cable.
Might be the wrong lug for the cable.
This is why I like to use a pin crimper.
I know its no longer code compliant but I can feel my way through a problem.
Last two crimps look like they are good I would use them.
rillweed
New Member
Q-Dog
¯\_(ツ)_/¯
How tight does the wire fit into the lug? The crimp looks good, but it looks a lot smaller than I would expect. Maybe the wire is too small for the lug?
bestconcreteblock
Solar Enthusiast
- Joined
- Dec 5, 2022
- Messages
- 136
Lug looks correct. You can see it is labeled 4 x 5/16 TE connectivity.
In my opinion, properly crimped fine stand battery cable lugs are going to look like this(very reduced).
That's perfect!
42OhmsPA
Who likes Electrical Gremlins?
That looks good to me.
As mentioned above. I'd try a 4+ and 4 together. I'm betting that works in one shot. If you only have a few to do proceed as you are.
rillweed
New Member
Ohh you meant one die of each together! Sorry I interpreted that wrong. I think I'm stuck buying more lugs and wire anyway so I may as well try this with what I have later. Will post back if I do
Went out to my wire box and found an older lug with wings that I felt was acceptable (rounded ends not sharp edges) at the time though no longer being used by me. Went ahead and hacksawed the lug in two so I could see if a cold weld happened. Looks thoroughly bonded. My picture below is not the best to view it but I will post it anyway.
bolhuijo
TechnoGeezer
Don't do what I did: I crimped, I examined visually, then I gave it a good pull. I started seeing copper coming out! dammit! I kept pulling. Copper coming further out! I kept pulling. More copper! Dangit how deep is the copper inserted into this thing anyhow?!? Slowly realize the copper is not coming out, the jacket is being pulled back. 
Small thin “wings”(extrusions) that can easily be trimmed off with a utility knife doesn’t really bother me. I’m concerned about re-indexing the die and re-crimping. Work hardened copper then a potential of shear or fracture as the out of shape hex is then required to reshape in another axis potentially weakening the grip on the cable. I don’t own any open throat crimpers mine are all the 16 ton and 10 ton. I have a collection of dies that I’ve modified(salvaged from crimpers that blew up). I’ve seen die markings wildly different and it seems like they are switching between “power lugs” and “starter lugs”(thinner wall). The OP’s die is definitely for a starter lug. I’d suggest with trying Selterm or Ancor brand and see if it’s any better. What ever works, stay with it for the future. Careful removal of some material from the hex of the die can be done to fine tune can be done but it’s a pain if you don’t have a milling machine but it can be done with time, file,vice and calipers. The center bottom flat is slightly widened and deepened in .010” increments and the sides blended into the corners. Do one side at a time and test crimp loading it onto the same test lug the exact same orientation as the previous crimp. The die’s open width is not changed. Most of the time on my die’s I find the die way too small and the next size up a bit too big, so I remove material down the split line of both sides till I get the perfect corners on the crimp. OCD is a curse but my cables are perfect.
I’d have no issues using that crimp.
When mechanically bonded (welded) as you show I feel the ears squishing out doesn’t weaken any bond that would fail after heat cycling, that’s one solid piece.
jorby
Solar Addict
I have the Temco crimper and have never had wings that thick. Looks like the die is too small.
rillweed
New Member
does someone mind explaining what the technical issue is with wings being formed if their still is a cold weld when looking at the lug cross section?
Many in electrical trades are perfectionist and want it pretty. But if complete cold weld with proper cross section is achieved, this defect is only aesthetic. Shouldn't affect performance at all.
DPC
Canada, Great already
The inspector is the one you have to please....
rillweed
New Member
I took off an offending terminal and cut it in half and the cross section looks great to me. I don't think I'm seeing a good reason to re-do these unless someone has some technical issue to share that could help inform me
Similar threads
