Homemade Battery Cable Lugs (Dirt Cheap!)

How to save a lot of money by making your own copper battery cable end lugs, or cable ring terminal connectors. These homemade battery cable lugs are ideal for auto, marine, solar, and much more for high current applications. Enjoy the video!
USED IN VIDEO:
16T Hydraulic Crimper Kit: amzn.to/37mm8wF
Inexpensive Hammer Crimper: amzn.to/37rCAMa
Rigid Tubing Cutter: amzn.to/2YgOSCU
Heat Shrink Kit: amzn.to/3fp6RhN
Reamer: amzn.to/3cSh6ZW
Type K Copper Pipe: Local Store or Plumbing Supply House
My Bench Vise: amzn.to/2XS6nuq
Mill Files: amzn.to/30safUJ
Mini Heat Gun: bit.ly/2MPoH0Q
Klien Plier/Reamer: amzn.to/3hjUUvh
(Amazon Affiliate & Banggood Links)
Link To Pipe Size/Wire Size Charts: i.postimg.cc/W48jwbts/chart-p...
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[@electronicsNmore]

Just so you know, you can also use an inexpensive hammer type terminal crimper to get the job done! I placed a link in the video description area. Thanks for watching, and thanks for your support!

[@smokingsolder39]

I don't think most people have a 16-ton crimper. So okay, how does it look/work with the hammer crimper? That seems more realistic.

[@electronicsNmore]

You can use a hammer crimper, but I really prefer the hammer type shown below. You can look online for deals. They work really good. www.toolsid.com/ancor/6-4-0-h-d-lug-crimper-mpn-701010.html?view=311100

[@stupidsmartmonkey]

I make cable lugs for work, there’s no difference except we use things like a 50-200t press and a 16-50t punch to squash and punch holes. Exact same process. Large drill bit and a belt sander removes all the burrs. Brass copper aluminium ect are all done the same as shown. We just stamp the logo as a trademark. You can do this all on a bench shop press.

[@ProjectFarm]

The finished product looks amazing! Thanks for another amazing video!

[@electronicsNmore]

Glad you liked it! I'm looking forward to Monday's video. Thanks for watching!

[@babylonfive]

A compliment from the Farm means a lot!

[@Bylga]

Legend 👏😲

[@mrbr549]

I have used this trick for years, but yours are much neater than the ones I make.

[@electronicsNmore]

Thanks for watching! Glad you liked the finished product. Please share the video link with others.

[@markhubanks3715]

I was just running some heavy gauge wire in a classic car and I needed some cable ends. I used your idea. Thank You!

[@jamespayne8781]

I’ve done this on several occasions. However I use the hydraulic press to flatten the end. There’s no secondary cleanup required and no need to hammer the edges down.

[@TrojanHorse1959]

Great video, idea, and execution, thank you! P.S. I've been doing this for many years, being poor sometimes leads to very useful money saving ideas. ; ) I got the idea one day while looking at a purchased ring terminal and noticing that they had made it out of copper tube. I thought, "I can do that too," so I did and the rest is history.

[@electronicsNmore]

Glad you liked the video Rob! Be sure to share the video link with others.

[@NAVYABHAN]

The best Engineer's in the World can look at a pile of junk,make what they need with the simplest of tool's,in the most ingenious ways! McGuyverism is a nod to the best!

[@electronicsNmore]

Thanks for watching Ben! Be sure to rate thumbs up, consider subscribing if you like a wide range of helpful and informative videos, and look over my extensive video playlists below for many other videos of interest to you. Taking one minute to share a link to my channel with others on social networking sites would be greatly appreciated. kzbin.infoplaylists

[@ACommenterOnYouTube]

Amen to that comment

[@ACommenterOnYouTube]

Kinda like a cook, they can go into the pantry and or refrigerator and see what they have and make a meal in their head with what they have ... thats a gift

[@dominicsianot2470]

This is so simple yet so appropriate!

[@frankbuckwalter9603]

Wish I had seen this video before I bought the terminals for my project!

[@rafaelcamilo2904]

Now you and I are two geniuses. Thanks

[@kevins3400]

So simple yet genius. Type K copper is a must.

[@electronicsNmore]

Yes, you want thick wall copper tubing. Thanks for watching Kevin! Be sure to share.

[@sapelesteve]

Terrific idea & nicely executed! I would never have thought about doing that. Thanks 👍😉

[@electronicsNmore]

Glad you liked it

[@fredschell8051]

A pleasure watching!

[@electronicsNmore]

Great to hear Fred! Be sure to share the video link with others. Thank you

[@jamaluddin823]

Great idea light up my mind thanks sir

[@Dutcharmytent]

This is the best guide/idea I have seen in my life.

[@darrylm3627]

Good Stuff,Great Tips😄👍🏿

[@vextrek6036]

Excellent video. Thank you for doing this.

[@electronicsNmore]

Glad you enjoyed it! Be sure to rate thumbs up, subscribe, and look over my extensive video playlists below for many other videos of interest to you. Taking one minute to share a link to my channel with others on social networking sites would be greatly appreciated. Thank you kzbin.infoplaylists

[@tattoojones23]

GREAT VIDEO

[@tectalabyss]

Hi Doug. Another winner !. Has always I liked,shared. All my best.

[@electronicsNmore]

Thanks Bobby! You're definitely in the 1% category that really go out of their way to help my channel grow.

[@jfarinacci0329]

Really good. Thank you.

[@electronicsNmore]

Glad you liked it! Be sure to share the video link. Thanks

[@thomasbrustad5596]

Great idea!! You just solve my problem. Thanks

[@electronicsNmore]

Glad to help. Be sure to rate thumbs up, consider subscribing if you like a wide range of helpful and informative videos, and look over my extensive video playlists below for many other videos of interest to you. Taking one minute to share a link to my channel with others on social networking sites would be greatly appreciated. Thank you! kzbin.infoplaylists

[@rwind656]

Very neat job.

[@electronicsNmore]

Thanks!

[@bandido7994]

I am going to try making them with aluminum pipe. Great video, thanks for sharing!!!

[@davidciaffa4711]

Good tip - I've done it a few times myself. Only thing I'd add is to clean the inside of the tubing to ensure optimum contact.

[@electronicsNmore]

Thanks for watching Dave!

[@Khlandestine]

clean with what?

[@davidciaffa4711]

@Khlandestine I was thinking a wire brush, like those used to clean the insides of tubing fittings before soldering. If that's not available, some emery cloth or sandpaper wrapped around a dowel would do the trick.

[@Khlandestine]

@@davidciaffa4711 thank you

[@brewsterly2927]

He did!

[@eebaker699]

So easy, I like it! 😁

[@electronicsNmore]

Glad you like it! Be sure to share the video link. Thanks

[@DanBurgaud]

1:00 you can use your hydraulic press to flatten this part. I inserted the cable first all the way to the end (as if its a ferrule), crimp half the usual way, and then flatten the other half using the hydraulic press' flat surface. (has to be a very strong hydraulic press though as this is one thick solid thing.

[@destinationeuphoriaselfdev2089]

Pretty cool

[@electronicsNmore]

Glad you liked the video!

[@Edmorbus]

Great video

[@electronicsNmore]

Thank you Ed!

[@billrayvan6857]

Sweet

[@ACommenterOnYouTube]

🤯 genius

[@scruffytech]

Very creative, takes a flexible mind see solutions to problems using available everyday items rather than just buy something. SpaceX can use ya!

[@electronicsNmore]

Thanks for watching!

[@orleydoss3171]

Very useful... 👍 Missing the watch. Lol

[@electronicsNmore]

Glad you enjoyed the video! I need to open up the watch to replace the stem.....another video. LOL

[@kurtlane6059]

I do the same however, I silver solder the terminals.

[@electronicsNmore]

I do that also, usually for size 4 and smaller. I have a video showing it. Thanks for watching!

[@batbawls]

Very nice

[@electronicsNmore]

Thanks!

[@TOMTOM-nh3nl]

Thank You

[@electronicsNmore]

You're welcome! Please remember to share. Thank you

[@dpyles9396]

This is an exceptionally good idea! Never saw this before. THANKS! BTW: Are you happy with that crimper?

[@electronicsNmore]

Glad you liked it! I'm very happy with it, especially for the price. I bought mine, it wasn't supplied to me for free. Be sure to look over my extensive video playlists below for many other videos of interest to you, and most importantly share. Thanks for watching! kzbin.infoplaylists

[@Christopherbever]

Brilliant

[@electronicsNmore]

Glad you think so! Thanks for watching

[@icghost2]

Always an excellent video - glad to see crimping get the love it deserves! So many makers solder high current cables only to discover that when everything else is copper, solder is the highest resistance material in the chain. Heat will build here first, making it the first thing to fail. I could only add one word of advice here...GLOVES. Copper has a burning desire to be one with you..your fingers, to be painfully specific. For weeks. Cut edges, burrs, the slightest tool marks on soft copper wire or tubing can raise an army of insidious bastards determined to educate you on how miserable your life can become from a simple splinter. Looking for diy inline crimps if anyone has ideas - ty sir!

[@electronicsNmore]

Glad you enjoyed it!

[@parkerazz4385]

Fantastic! Now I just need to source the copper cables.

[@electronicsNmore]

Copper welding cables are good.

[@brucesamuelson7541]

Had to watch it through to say "Touche" shrink wrap and all just like I do it!

[@electronicsNmore]

Thanks for watching Bruce! Have a great weekend.

[@DiyEcoProjects]

These are BeauUUUutiful. Thank you

[@electronicsNmore]

You're welcome!

[@DiyEcoProjects]

@@electronicsNmore hmm... so how to crimp without a 16ton crimper. hmm. Perhaps i can crimp it using the weight of my car lol

[@electronicsNmore]

@@DiyEcoProjects You can buy a hammer type crimper.

[@DiyEcoProjects]

@@electronicsNmore ahh ok. Thank you, all the best

[@Khlandestine]

What size copper tubing for 1/0 AWG?

[@michaelagold4580]

Thank you for the video. That was Easy-Peasy. BUT, the money you saved making the lug won't cover the cost of the file that gets dull from your MIS-USE!!! Never, BUT NEVER use a file like you did in this video! Always push the file in a forward motion. When you reach the end, lift the file, return to the starting point, and push the file forward again. Continue this method until you achieve the finish you desire. Never DRAG a file BACKWARDS to the starting point. This causes the teeth to be broken and/or become worn beyond use (dull). I learned that in 1979, from a LU 798 Pipeliner. 45 years later, I still have that ½ round bastard file. The ½ round side is a kind of worn, but the flat side is in pretty good shape. It's a 12 in Nicholson, made in the USA.

[@electronicsNmore]

There's zero chance of damaging a file made out of Steel on copper

[@asderven]

Great video, I am going to build my own lfp battery, find your instructions very helpful. Just one itsy bitsy question. At 4:12 you mentioned terminals polished to remove oxidation, what does that mean? what kind of polish? I am a person with 0 knowledge about these kinds of things, so I have to start from asking very basic questions :D.

[@electronicsNmore]

I used a small stainless wire brush and 000 steel wool pad. Be sure to watch and share my lfp battery video below. Thanks! kzbin.info/www/bejne/boqqoHaJocqUkLc

[@macEboy]

Well done my South FL brother. Could you do a "How to survive a Hurricane power outage" 3-4 day power outage in style? Maybe using a Solar system and maybe a generator mix? Thanks!

[@electronicsNmore]

I'm ready. :-) Hopefully we don't get any. I have a Generac inverter generator 2000W start, and a few high powered portable power stations that can be charged using my larger solar panels. I should be OK, but no AC of course.

[@darthbubba866]

Great vid, as always. Thanks also for the crimper links, not a tool I already owned.

[@electronicsNmore]

Glad you enjoyed it. Thanks for watching!

[@omniaparatus1890]

Nice

[@electronicsNmore]

Thank you! Be sure to share.

[@pulesjet]

Done it this way more then a few times. And contrary to everyone's musings 1/8 x 3/4 Aluminum Strap makes fine Bus Bars.

[@electronicsNmore]

Aluminum bars are fine, just use some No Alox on the connections.

[@stormyyoung6344]

You can turn jaws over on crimper and use flat side to smash cooper pipe and have no hammer marks

[@electronicsNmore]

Yes, that does work, but the jaws are only 1/2" wide, so you'd need to do it 2- 3x overlapping, then you'd get lines across the connector. Thanks for watching!

[@CoconutPalmPictures]

Will type L copper pipe work? It's very hard to find type K.

[@1amazingj]

Another Great Video. Thank You 🙃

[@electronicsNmore]

Thank you! Remember to share.

[@PecanPie1102]

Thanks a bit more affordable option to the Milwaukee M18 mcm600 crimper .

[@electronicsNmore]

Yes, the hydraulic crimper is worth every penny. Thanks for watching

[@minus3dbintheteens60]

I'm very impressed! Next, how to crimp the wire without an expensive crimper

[@electronicsNmore]

You can use a 20-25 dollar hammer crimper.

[@JT-lq4yd]

Great job on the terminal lugs. My tool box needs a burr removal tool as shown. Who makes it? Thanks in advance!

[@electronicsNmore]

Thank you. I placed links in the video description area.

[@JT-lq4yd]

@@electronicsNmore Should have read the description... added to cart. Thanks!

[@SolarizeYourLife]

What size wire for the different copper pipe sizes???

[@electronicsNmore]

I posted a link in the video description area.

[@00Skyfox]

I've made these before out of copper pipe, but since I don't have a crimper I just heated up the lugs with a blow torch, filled them with molten solder, and stuck in the fluxed cable to make a completely solid solder connection. BTW, I never did find that chart of pipe diameter to cable gauge size.

[@electronicsNmore]

That works, but you don't want to overheat the connection causing all the solder to wick up into the cable making it stiff. I posted 2 charts, one shows wire size OD, and the other shows pipe side ID.

[@00Skyfox]

@@electronicsNmore All I can see in the video description is amazon links and a paypal link. Where are the chart links?

[@olenaerhardt7725]

Thank you for the informative film. Can you make 90 degree battery lugs?

[@electronicsNmore]

No reason why you couldn't bend the flat end. Thanks for watching!

[@olenaerhardt7725]

@@electronicsNmore Thank you for your opinion.

[@David_11111]

yay

[@user-jc2ez6ig5z]

I like the music and annotation format. Good music.

[@electronicsNmore]

Great to hear. Thank you!

[@AGhostInTheMachine]

Is it possible to buy just the crimping dies and use them in a vice instead of the whole $60 hydraulic press device?

[@electronicsNmore]

Hi Theo. Yes, look on Ebay using the search term: "replacement hydraulic crimp dies"

[@ezyjack826]

have to replace the bolt on my battery terminal. what kind of bolt should I use?

[@electronicsNmore]

Usually a bolt that's plated brass

[@techs5564]

every video here is useful.

[@electronicsNmore]

Glad to hear that!

[@techs5564]

@@electronicsNmore really, it's true. I copied many of your ideas at field. Thanks a lot.

[@mikecrawford715]

Where do you get that crimper?

[@electronicsNmore]

Hi Mike. There should be a link in the video description area

[@mrhalfstep]

Can you solder the tubing to the cable? I realize that the solder joint would probably have to be made first, if you don't want to melt the insulation or have to strip it way back and then replace it with shrink tubing, then the tubing could be flattened and shaped into a lug. I ask because I don't have any sort of crimper, hydraulic or mechanical and would like to know if a solder joint would be as good, conductively, as a mechanical joint.

[@electronicsNmore]

You can, as demonstrated in my other video below, but this lug is too large, I usually do it for smaller sizes. kzbin.info/www/bejne/m5bHo3iKe79mjdU

[@mrhalfstep]

@@electronicsNmore I watched your video and thank you so much.

[@krusherkid]

Great video. Other than the lack of commentary during the process. Makes it seem like one of those life hack channels that just make videos for the views. Commentary>Background music.

[@electronicsNmore]

Those hack channels do better than my videos. LOL

[@krusherkid]

@@electronicsNmore This may be true, but most of the"hacks" they're coming up with now are just pointless. No one wants to use an old cut up plastic water bottle and double sided tape to hang up your toothbrush. Your hacks and tips are actually useful. People get tired of watching crap. But they'll always want useful information, which you consistently provide in your videos.

[@electronicsNmore]

@@krusherkid Yes, many are pointless, and sadly they're making a lot more money than me,. My videos have helped millions of people save a lot of money. The wrong people end up making all the money.

[@krusherkid]

@@electronicsNmore slow and steady. Channels that rise quickly fall quickly.

[@electronicsNmore]

@@krusherkid Any slower I'll be going backwards! LOL I think after 10 years I should've been doing way better than I am.

[@ZiyanJunaideen]

Do we need a 16ton crimper for that or can we use something around 6ton?

[@electronicsNmore]

You can use less.

[@ZiyanJunaideen]

@@electronicsNmore thank you

[@tarstarkusz]

I don't see anything in the description matching wire size to pipe size (0:44) That would be something very useful to have even down to rather small gauge wire. You can get some fairly small copper tubing.

[@electronicsNmore]

I was showing LARGER sizes, not smaller. 4ga to 4/0 range. All you have to do is look at the 2 supplied charts and compare the ID of the tube to the OD of the wire. Use a tube that's slightly larger than the OD of the wire.

[@tarstarkusz]

@@electronicsNmore There are no measurements in the description to any charts nor are there links to anything but amazon that I can see. For some reason, I do not see anything related to sizes, just the amazon links, some patreons, a paragraph about sharing and subscribing.

[@dougaustin1328]

It is not hard to find,hard coppercimes in 10 ft lgths,it tends to split if you pound it down or vice it flat,soft copper comes in a coil,that is what you want,its refrigeration tubing,found ard the world easily.😊

[@yeahrightmate]

Where do you get the copper tube from.

[@electronicsNmore]

Hardware store.

[@yeahrightmate]

@@electronicsNmore Nope, not unless I want to buy enough to go into production.

[@babylonfive]

Quick comment: I much prefer your voice and no music. It is more entertaining compared to split attention on reading and watching two things... IMHO. Put the text of the script in the Comments section if you want them documented.

[@electronicsNmore]

Appreciate the input, but I do like to relax once in a while and make the video as I did. I get tired of spending a lot of time talking to only end up with 3000 views.

[@NavinBetamax]

HELP !!! I am not able to see the Descriptions section in full. I am not the only one and this is happening to not just this KZbin Video...it is happening to all other Video Subscriptions also ! GOOGLE is upto it's TRICKS Again !!!

[@electronicsNmore]

I think it's your browser. Try another phone or computer.

[@NavinBetamax]

Thanks....will check on desktop !

[@TechsScience]

Well, we should help each other to grow

[@Masteflex30]

Great trick when you're in a pinch, but not time effective.

[@fn0rd99]

Didnt you make this video years ago?

[@electronicsNmore]

I made one when I was just uploading videos for the hell of it, and in the other video I soldered the terminal.

[@oscarmonterrosa1840]

Is this school for 5 years old.??

[@electronicsNmore]

Your comment definitely came from a 5 year old. 😂 Grow up.

[@PuchMaxi]

Hey, this seems familiar! watch?v=RpFb_Yxl_hA I guess I'm a long time subscriber!

[@electronicsNmore]

I have a much older video that's popular. It was made when I was living on an island in the Bahamas. Back then I uploaded videos to my channel for fun, now it's a job, so the quality of my videos are a much higher level now. In that video I soldered the 4ga connector to the cable. Thanks for watching!

[@randallsemrau6911]

I was doing great.... until the CRIMPER

[@NO-background-music-in-videos.]

must be stolen content since it had schit music laid over it

[@electronicsNmore]

Grow up

[@rokinrandy]

Nothing cheap about that. Unless you’re a customer that calls plumbers crooks. Build this and now you see why shits expensive

[@electronicsNmore]

It's far cheaper to do what I did using a copper tube than buying a connector.

[@tunafish3216]

No voice WTF if we go this route I’m going away.

[@electronicsNmore]

After over 560 videos where all I do is talk, I'm more than entitled. That comment was a foolish one, I keep very close track of my true supporters. The video was very well done, and there were annotations explaining everything.

[@NETBotic]

@@electronicsNmore Do more like this just to troll him/her/it.

[@AGhostInTheMachine]

bye

[@DoNotResuscitateAgain]

Great stuff! The only thing I would possibly do different is tin the copper connectors, especially if used in an outdoor environment.

[@electronicsNmore]

Yes I have a video on my channel showing me tinning the copper connections.