How to get the 2/0 stranded alum wire into a 2/0 alum lug?

[opticalcarrier]

This power cable from EG4 for their batteries is marked as "AWM STYLE 3512", it is 2/0 awg very finely stranded aluminum. And try as I might I cannot get the wires into this 2/0 lug. I've even tried using tiny wire to wrap the exposed wires really tight in on themselve, still cannot get it to fit into this 2/0 lug.

I cant get it into a 3/0 awg lug, and even that was with a bit of difficulty

Im sure theres some trick that Im just not aware of?

 

[42OhmsPA]

Did you try this?
Post in thread 'How to connect the "black" style JK-BMS with the short B- and P- leads?' https://diysolarforum.com/threads/h...th-the-short-b-and-p-leads.82942/post-1076500

 

[~Yuri~]

This power cable from EG4 for their batteries is marked as "AWM STYLE 3512", it is 2/0 awg very finely stranded aluminum. And try as I might I cannot get the wires into this 2/0 lug. I've even tried using tiny wire to wrap the exposed wires really tight in on themselve, still cannot get it to fit into this 2/0 lug.

I cant get it into a 3/0 awg lug, and even that was with a bit of difficulty

Im sure theres some trick that Im just not aware of?

I can offer you a simple and effective way. Make two circular cuts in the insulation at the end of the wire. The first piece of insulation is removed, the second one is carefully moved to the edge of the cut wire, which should be inserted into the terminal for crimping. Aim carefully and drive the wire into the hole. Then remove this piece of insulation and insert the wire as far as it will go. I believe you will succeed!

 

[Rednecktek]

I have the same problem with lugs sold at my local electrical supply house. The OD of the lug is the same as the ID of the wire insulation. The only fix I've ever found was up sizing the lug. Fortunately that ends up being a REALLY tight crimp.

 

[opticalcarrier]

Well I accidentally stumbled across what apparently is the correct solution here.

I had just resigned myself to getting some alum 3/0 lugs and using them even though this cable is 2/0. However when I got them in the mail they were marked physically on the lug as 3/0 and also as 2/0 flex

So apparently this very finely stranded flexible 2/0 power cable is expected to use a 3/0 lug after all?