I had to cut my 8GA output cable from my generator to be able to pull it out and replace the exhaust elbow.
How do I connect them back up? Butt crimp connectors?
Meridian, I'd send you mine on loan, but you could probably buy it for the round trip shipping charges.
FlyWright: I ordered one of these on your recommendation. Agreed that the die sizes are all wrong, but at $40 after discount from HF it is still really good value. I would not be without it.
Rather than a butt connector, you could put on some ring connectors and attach to a busbar - easy to disconnect should you ever need to remove it again.
How about a butt splice a cold chisel a hammer and some solder.
Works for me .
Then again I do many things with what I have around.
Sd
Using a cold chisel and hammer is abut the same as using the $50-$60 dollar hammer crimper West Marine sells...you may actually do it better. But nothing like a good crimper...they are pretty impressive to what they do to the wire and connector connection.
Even ABYC says soldering is OK as long as a mechanical fastening is also employed and suitable support is provided.
Is soldering OK if you use a wire nut as a mechanical connection?
OK I'm wrong .................
Being wrong once in a while is nothing to be ashamed about. None of us can know everything about everything.
Gents,
You might want to read this paper: http://www.newark.com/pdfs/techarticles/tyco/ET.pdf
The gist of it is that a proper crimped connection can be superior to a soldered one. Why? I quote:
While other methods are considered strong mechanical connections with high-performance electrical properties, crimping provides strength under constant load in tension and severe vibration. Crimp connections tend not to crack or creep under sustained loads. Fatigue is not an issue. Since the mechanical performance of a crimp is robust and sound, the electrical properties are less likely to degrade. In short, static heating is avoided when good crimping practice is followed.
Soldering also has the disadvantage that it will compromise the insulation adjacent to the solder joint. Crimping is the recommended connection method for military and aerospace use.
Here are my recommended steps in ensuring a long-lasting, electrically-superior connection:
1) Use high-quality tinned wire.
2) Use a heavy-gauge tinned terminal.
3) Use the correct crimper for the gauge, and ensure that the crimper crimps the entire circumference.
4) For high-current applications, finish the joint with adhesive heat shrink to exclude all oxygen.
Here's my main DC electrical switchboard. It's now been ten years since I installed it, and there has not be one single problem with a connection.
Scott Welch
Island Eagle
Never disagreed that proper crimping is the best way...it's just not the only way...........
I think when people come her looking for advice, we should try to give them only good advice.
Choices and concepts are better , as "Best" frequently requires special parts and special tools .
Special everything means ordering/flying in parts and bribing the customs guy .
A repair that works and can be done underway , in nowhere, can always be replaced sometime for perfection.
I had to cut my 8GA output cable from my generator to be able to pull it out and replace the exhaust elbow.
How do I connect them back up? Butt crimp connectors?
It's not like everyone in this forum stays TOTALLY on topic every thread.