How To Crimp & Terminate Battery Cables Like A Pro | JS Tech Tips
This JS Speed tech tip provides a comprehensive guide on battery cables for automotive projects, focusing on cable types, connections, cable sizing, and crimping techniques. It covers common battery cables like PVC-coated, welding cable, and stereo-related copper-clad aluminum cables, emphasizing the superiority of actual copper cables for reliable performance. The video advises against using bolt-together connectors and solder joints for durability reasons, recommending crimping instead. Various crimping tools are reviewed, including hammer, ratcheting, and hydraulic crimpers, recommending the hydraulic hex crimper for best results with cost-effective options available. For cable sizing, the guide suggests using 2 gauge for front-mounted batteries and 1 gauge for trunk-mounted configurations, particularly in high-demand or supercharged engines, to avoid voltage drops and starting issues. The speaker shares personal preferences and practical tips to avoid electrical issues and improve connection longevity.
0:00 Intro
0:10 Battery Cable Connections
0:34 PVC Battery Cables
1:07 1/0 Welding Cable For Battery Connections
1:32 Copper Clad Aluminium - Stereo Cable!
2:14 Grounding Straps For Batteries
2:46 Battery Terminal End Connectors
3:26 Battery Top Post Connectors
3:54 Normal Battery Terminal Ends - Copper or Nickel
5:06 Basic Hammer Crimper
6:00 Ratcheting Crimper
6:39 Hydraulic Crimper (Hex)
7:06 How to Crimp Terminal Ends
8:58 Using the Hex Crimper
10:12 Cable Sizes For Batteries
🔋 Use high-quality copper battery cables, avoid copper-clad aluminum cables.
🛠️ Crimping battery cable ends is preferred over soldering for durability.
💪 Avoid bolt-together connectors; crimped connections hold better.
🔧 Multiple crimping tools discussed; hydraulic hex crimper provides the best results.
⚡ For front batteries, 2 gauge cable works; use 1 gauge for long runs or high-powered engines.
🔩 Nickel-plated lugs resist corrosion better than raw copper lugs.
🚗 Proper cable sizing and secure connections help prevent starting and electrical issues.
🧰 Crimping vs. Soldering: Crimping creates a more vibration-resistant and reliable electrical connection, especially important in race cars where solder joints often crack under stress. Investing in a quality crimper tool is a small cost compared to the headache of failed connections.
⚡ Cable Material Matters: Copper strands outperform aluminum, even if the aluminum is copper-clad. Copper cables offer better conductivity, greater durability, and are essential for high-performance automotive electrical demands.
🏎️ Sizing for Performance: Larger cables (1 or 2 gauge) reduce voltage drop during high current draws, critical for high-compression or supercharged engines. Undersized cables can lead to slower starter motor operation and poor engine starting.
🛠️ Crimp Tools Variety: Hammer and ratcheting crimpers provide good results and affordability, but hydraulic hex crimps offer the best, most consistent connection. The hydraulic tool’s ability to produce a full hex crimp ensures better cable compression and longevity.
🔩 Corrosion Resistance: Nickel-plated terminals resist corrosion better than raw copper, improving connection durability especially in automotive environments exposed to weather and moisture.
🌟 Avoid Bolt-Ons: Bolt-together cable connectors are prone to loosening and poor contact, leading to electrical issues. Crimped connections provide firm, reliable grip that lasts.
👷 Practical Application: The advice to carry multiple crimpers and cables in different locations (truck, toolbox) maximizes readiness and quick troubleshooting ability—key for race or road use.
This guide distills practical, tested advice on battery cable preparation and installation, helping users avoid common pitfalls and ensuring dependable electrical performance in automotive projects.
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