Modding a ground clamp?

[dragoneggs]

Okay this might be a silly one but I am changing my Miller simple ground clamp to a Magswitch ground clamp. The wire gauge is quite small on my 211 and the Magswitch has a 7/16in bolt. So... I finally found a copper crimp terminal at O'Reilly's autoparts store for two bucks.

Problem is it is made for 2/0 wire. Any suggestions on how to join this elegantly?

 

[snymat68]

Option 1: Buy terminal correct size for wire. Crimp with vise.
Option 2: Buy larger gauge wire and crimp with vise.
Option 3: Strip off extra insulation from existing wire and double or triple the end of the wire over to fill up the terminal. Crimp with vise. (Optional: Fill with solder using propane or mapp torch.)

 

[lennyzx11]

Option 1: Buy terminal correct size for wire. Crimp with vise.
Option 2: Buy larger gauge wire and crimp with vise.
Option 3: Strip off extra insulation from existing wire and double or triple the end of the wire over to fill up the terminal. Crimp with vise. (Optional: Fill with solder using propane or mapp torch.)

Option 3 works good.

Alternatively, buy an appropriate sized piece of copper tubing and smash, crimp, and drill it. Been working good for 10 plus years on my 10000 lb warn winch.

 

[dragoneggs]

Thanks for your reply!

Option 1: Didn't find one. If someone wants to point me to where I don't have to buy a pack of 10 or 25 :thumbsup:

Option 2: I could increase the wire gauge to 2/0 and I think it will actually fit the routing and terminal inside the welder. Really didn't want the expense of a 15ft wire. I actually bought a second terminal in case I mangled the first one. See pic.



Option 3: What I was planning to do unless someone had a brilliant idea. Thinking at least a tripler.

 

[dragoneggs]

Option 3 works good.

Alternatively, buy an appropriate sized piece of copper tubing and smash, crimp, and drill it. Been working good for 10 plus years on my 10000 lb warn winch.

Funny you say that... when I walked out to take a pic of the inside terminal, I was thinking... I must have something I can jamb in there. All I see hanging around is 1/2in copper plumbing pipe.

 

[bcp]

Discard the large bolt and use a bolt and washers that fits the small wire terminal you have. If it makes you feel better, make a bushing to fit the larger hole in the clamp.

Bruce

 

[RNeumann]

How about finding the right sized terminal lug!?!?

Second choice is solder. Put the terminal in the vise with the end up. Fill with solder and put the wire in the terminal until it cools.

 

[dragoneggs]

How about finding the right sized terminal lug!?!?

Second choice is solder. Put the terminal in the vise with the end up. Fill with solder and put the wire in the terminal until it cools.

As I mentioned, if someone can point me to the right sized terminal w/o me having to buy a pack of them, please fill me in.

Yes, I do plan to crimp and solder. My other thought was to notch the new terminal lengthwise to allow some overlap of the sleeve. Just to make it look more like it belonged.

 

[newbury]

I had a similar problem - now I've got bags of Anderson type connectors, terminal lugs of many sizes, Anderson connectors on my winches, my jumper cables, and a pretty good but inexpensive crimper.
But if you don't ever see the need for hooking other stuff up I'd cut, smash, crimp and drill a piece of Cu pipe.

 

[Big Barn]

As I mentioned, if someone can point me to the right sized terminal w/o me having to buy a pack of them, please fill me in.

Yes, I do plan to crimp and solder. My other thought was to notch the new terminal lengthwise to allow some overlap of the sleeve. Just to make it look more like it belonged.

I would do that if you can’t find the proper terminal lug easily. A proper cable crimping tool should then be used instead of just squishing it in a vise.