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.

 

[jaxs]

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.

Option 4, 2" long piece of smaller copper tube soldered/brazed to interior of pictured terminal,crimp wire in small tube.

 

[dragoneggs]

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.

I have a crimper... I am thinking I 'V' cut the sleeve.

Terry, I am sure you can appreciate the thought going into this?

 

[WranglerX]

Keep traditional clamp... Rumor has it magnetic clamps are not that good...

Dale

 

[dragoneggs]

Keep traditional clamp... Rumor has it magnetic clamps are not that good...

Dale

WHAT! You are bursting my bubble. I was so excited to get this thing in action.

 

[WranglerX]

WHAT! You are bursting my bubble. I was so excited to get this thing in action.

Yopu need to address this on a welding forum.....

Experience of 38 year of working with power cable and such, get proper size lug, meaning hole for bolt and for cable size, If you don't have proper tools go to good welding supply and they should have repair lugs and proper crimpers....Any place that sells bulk welding cable should have proper lug... Even Tractor Supply...

This close to what you need

Thomas & Betts - 5415 - Lug; One Hole; 1/4"; Blue; 6 AWG; .53" Lug Sz; 1.23" Overall L; .44" W; .31" Cable Sz - Allied Electronics & Automation

Or

Thomas & Betts - 5413 - Copper One-Hole Lug; #8 AWG; 1/4" Bolt Size; Die Code 21; Color Code Red - Allied Electronics & Automation

IF neither of these are correct tell me exact size of cable and hole size you need I can supply information on proper lug...

Sorry, didn't know you lived in a bubble....

Dale

 

[dragoneggs]

But, but, my friends are here!

Ha... I didn't try Tractor Supply... will check them out tomorrow. Agreed a proper gauge receptacle with a 7/16in eye is the right way to do it.

 

[Big Barn]

I have a crimper... I am thinking I 'V' cut the sleeve.

Terry, I am sure you can appreciate the thought going into this?

That would work I think. But Dale and others are correct. Getting the appropriately sized lug would be best.

 

[dragoneggs]

Well maybe the V cut will be 'temporary' until I find the proper terminal.

 

[jaxs]

Keep traditional clamp... Rumor has it magnetic clamps are not that good...

Dale

Could be but when was the last time you saw someone get excited because their friend has a traditional clamp? Only a week ago I took my postman to the shop to see my custom colored leads. I'll be adding a mag ground soon as momma pays me my monthly allowance for keeping my mouth shut.

 

[Big Barn]

Keep traditional clamp... Rumor has it magnetic clamps are not that good...

Dale

I have traditional but I use my magnetic one mostly.