VAN BUILD TIP SERIES: Safe and proper wire crimps are extremely important in your van build.

As the electrical systems in van builds become more powerful and complex, the foundation for safety is the ability to properly crimp your wire connections. As a professional custom van builder, I decided to make the investment in a tool that pretty much guarantees a proper crimp every time. And as it turns out...I love it! It was well worth the expense.
#customvanbuild
#onahumbleroad

[@leonardsackett9568]

PS: full disclosure.....have not watched your vids for a year plus. Did make a copy of that screen door you made several years back AND STILL LOVE IT. Have a Pleasure Way OnTour 2.2 coming in in November and starting to make a list of mods I want to do. So here I am again looking over your great ideas. Side door, front cab overhead shelf, Lagun installation tricks, etc. Thanks again for all the well thought out ideas. Also switching out the two 100Ah lithium Eco batteries with two SOK 206Ah batteries in about the same physical space. The 12v 5cf refrig only draws 200ah per day but the RV has induction cook top. We dry camp a lot. Sorry getting diarrhea of the mouth.

[@leonardsackett9568]

I saw in the vid you had a couple of the smaller wire size crimpers that have rotating dies to crimp. I got one of those off Amazon (haisstronica Battery Cable Lug Crimping Tools-Wire Crimper Tool-AWG 10 8 6 4 2 1/0-Battery Terminal Crimper for Heavy Duty Wire Lugs,Battery Terminal,Copper Lugs Terminal ) and found it not to be safe. The dies when used as directed made did not make tight crimps on 4 ga wire. If you rotate one of the dies to one size smaller wire and crimp several times it was "good". I sent it back and posted that it was a safety hazard (no surprise my post was not posted). Your power tool for a serious builder is nice.

[@preluded]

I used to crimp DC cables for 48v Telco equipment (central office). I wish I had one of those when I was doing that work, that is truly amazing to crimp a 4/0 that quickly and easily. Anyway, one nice thing about Telco lugs (mandated by the bellcore standards) was that you had both extended barrels in some cases for dual crimping and an inspection hole at the top of that taper so you can confirm the wire was properly inserted. They also had dual stud holes as well, so you had tons of surface area for connection points. One thing I would highly recommend is investing in high quality shrink tube. There is a whole world of speciality heat shrink made by the likes of Tyco, some are even used for marine repair on subsea cables (which is my industry). Anyway, I would at least use double wall adhesive shrink like the ones Ancor resells, or find a Tyco, etc dealer. It provides some additional mechanical strength and wear resistance. Btw the crimp mark is very useful for issues down the road...if there is a fire etc it could be used as evidence to understand the cause...I've run into several problems where I took the lug apart and found it was crimped incorrectly...probably because someone lost the right die. Fortunately I've not seen it cause a fire, but it did melt the plastic around a lug pad on a piece of Telco equipment. It's also standard to use NoOx to coat the wires in telecom before you insert the wire in the lug...this is another guard against corrosion (Telco power plants are expected to last 30 years at least). You just need a tiny bit, and put it on the face of the lug after making sure all surfaces are very clean. Dust can actually cause heat as well...I have seen a fire (high voltage) caused by contamination between the conductors. I can go on and on, having been involved with 200kw+ DC systems, there are a lot of details to keep them reliable that comedown to patience and redoing work that might not be perfect. Senior guys always made us restrip of we even clipped a single strand on a wire.

[@mayinnlin1879]

Thank you so very much for sharing George! Amazing job! 👍❤️

[@HumbleRoad]

Glad you enjoyed it

[@GreganDunn]

Looking forward to seeing you build your first all electric camper van!

[@HumbleRoad]

Can't wait!

[@gurugee2112]

Cool tools for the Cool VanMaster!

[@HumbleRoad]

Yes they are!

[@carbonrrpilot]

Ahh its nice to have George back!!

[@lynnekerr3890]

It is.

[@JGSuttonJr]

Man you got way too much swag and coolness to ever crimp.

[@HumbleRoad]

😂

[@1monagale]

Tool envy! Crimp tool looks great! Step by step is mind blowing to now understand. Thanks! I’m waiting for a hammer crimp delivery, fine for my first van build.

[@carissahill3414]

Hi George! To add to my last comment, A better design for the chair and or the step up to the bed area that takes up a bunch of space. I have been watching months and months of van build tours and you are WONDERFUL! Wish I could have you build my van. I have many special needs. Gonna be using many of your methods.

[@Toaster-v1z]

Good stuff. It's time we went to 24v systems.

[@dieselrugg]

wow! that crimping tool is awesome!!!

[@sanjeevbhalla2506]

Beautiful crimping tool

[@johnplyler7054]

I have the same Chinese crimper and I had to go through three dies before I was satisfied with my 4/0 crimp. 120, 95, & 75. I also drilled a 1/4" hole in the lug (some come open) and melted in about a foot of solder. Just a little to stop oxidation. The solder did not go past the lug and stiffen the cable. I really enjoy your video's. I am so glad you are back!

[@gurugee2112]

FYI, if the crimp is done correctly, you should create a cold flow connection that is gas tight. T&B used to have cutaways of a completed crimp showing a solid mass when done.

[@janetdupree6353]

⭐️

[@LordDurak]

Thanks George!

[@latergator3367]

Thanks, good info !

[@GirdHerd]

I use a utility knife to slice the 4/0 insulation along the strands to remove the insulation after using the special cutting tool. It works well and doesn't cut off any of the strands.

[@billvanarsdale]

I am putting in 612 AH battery bank and 4000 watt inverter, mostly for induction cooking and will get professional help for making sure I have solid wire connections and proper installation. This is one area of a van build where there is no room for error. Your videos properly raise the cautions of getting this right. If you or any of your viewers know of a good business that can do this in western Massachusetts/Albany area, I’d appreciate the lead, or I may just go find a boat electrician on Cape Cod while I wiggle my toes in the water. Next, professor, I’d love it if you’d do a video on how you attach wood surfaces to extruded aluminum with no framing showing, and and also how to support and frame windows.

[@leonardcroft1467]

Hi George Always enjoy your Videos !! Thanks

[@vidguy007]

When I installed my solar I made up the battery cables at West Marine on their rigging bench, since my ratchet crimpers are for smaller gauge wire. They sell the correct tinned wire, lug connectors and heat shrink. It did not occur to me that their crimp tools are meant for stainless cable and it’s fittings, not for the battery cables I was making Everything appeared to be correct. The radius of the connector matched the radius of the crimping tool.. One of my battery cable ends pulled off on a trip, so I used vice grips to reattach the end, squeezing it from the side edge like a pinch Now I use my infrared thermometer to make sure there’s no resistance to the cable ends and will have to tear everything apart to install properly swedged cables

[@nbc902]

Great video

[@doma368]

Very nice tools and attitude.

[@Jayda08]

Before you said the price of the tool, I was guessing its around $1,500. But when you said $4,500 I almost choked on my tea. In all fairness I think the price is justified given the fact you will save a lot of time and energy when you are doing so many crimpings everyday.

[@HumbleRoad]

The $4500 includes a full set of Dies

[@extectic]

Working with heavy gauges is definitely a challenge. 12/24 volt wiring in general is a lot easier. I don't really like using crimps if it's avoidable for extensions and stuff, I tend to use Posi-lock connectors instead. Basically up there with soldering but much easier to do.

[@angelaborgen9705]

Such great info … so good of you to share your knowledge 👍😁

[@SheaDesign]

Using the 16 ton yellow crimper I just back off the valve for a moment the pull captivated pin off the end instead of pumping the full stroke of the hydraulic cylinder each time. I also mark the flat of the lug on the wire and then square it up in the crimper, apply maybe half a stroke to hold it then align and push the wire in place. 3 or 4 pumps and it is done. Second crimp fwd. I see people keep pumping even after the dies collide, then I see their broken crimper. Most of the dies with that 16 ton are for really big wires (way beyond 4/0), kinda lacking granularity on the more useful sizes we are all installing. Agreed, nice to have you back a booming!

[@anthonymarino4260]

This is the Gold standard

[@TOTALLYRELAXED]

The cutting tool you used to cut away the outside layer of the 4/0 wire is VERY similar to a plumber’s tool to cut pvc and abs pipe…they look identical. In fact I thought that’s what you were using! Always intrigued by your DIY lessons! Stay safe, my friend! ~Jim~

[@mjremy2605]

Yes, good point.

[@OrganicHealer]

I was not expecting you to say thousands. I was guessing 350. You make great videos

[@allenahale1]

Silly me, I was thinking $1,200.

[@birdnest5814]

I’m enjoying these videos 👍💕😊

[@cheryl7917]

Thanks for another useful video, look forward to every one of them!

[@HumbleRoad]

My pleasure!

[@sdsuper1030]

Unfortunately I have never had luck with crimpers. If they don't fail the pull test right away they fail when maneuvering the cable or couple years down the road when removing cables to change batteries. An older Asian gentleman taught me years ago using a hammer and solid surface like concrete floor and mashing it flat. I had a tech laugh at me one day so we did a pull test with a come along and all his failed way sooner than mine no matter what he tried to do to make his better. Hammering them doesn't look as good so heat shrink is a must for cosmetic purposes. We also tested my way versus precrimped ones from companies and my way did better than all but 1

[@hardlyworkin3603]

No wonder your conversions take so long for perfection. One crimp is time consuming. Not many builders would pay that much for a premium tool. Hope it lasts a very long time.

[@maggiebrattoli383]

You must get Milwaukee to endorse your videos and better yet, they should send you the products for FREE. contact them. They will. Great video George. 🙏

[@johnhaywood3351]

Can you give us the model number of the basic tool and individual dies please. I am having trouble deciphering Milwaukee’s catalog.

[@PhilipWarda]

George, you just made crimping lugs sexy. I will never underestimate you 😂

[@cesalt2408]

This series is a real treat. Such a wonderful start to my day!

[@ovmn]

Another great video :)

[@jamesgill5511]

For anyone that doesn't want all the exercise of a hand pump hydraulic crimper, but also doesn't want to dish out $4K+ for a cordless one, you can get mechanical bench mount crimpers that will do 6 AWG to 4/0 cables for $275-375. They've got long handles so you can put some body weight into it and they use fulcrums like a bolt cutter to multiply that force further. A 125# teenager can easily make solid crimps with one swing of the lever. The dies take a a little longer to change, and you have to do all your crimps away from the vehicle since the crimper needs to be bolted to a bench, but I used one for years making new battery cables when I worked on school buses.

[@jerseyshorefabricators7431]

@jamesgill agreed. I use a similar setup. Not as cool as pulling the trigger, but a fraction of the cost.

[@kentmparker]

What do you think about soldering the connection?

[@HumbleRoad]

Solder can break free under the vibration of the vehicle.

[@gurugee2112]

And soldering requires a good mechanical connection as well. Solder is for electrical connection only, not strength.

[@MykSr]

Your videos are such a treat, you make my day so much better. Outstanding content as always. Educational and entertaining … it’s a tough combination to beat❗️😎

[@DallasD_]

⚫️ Badabing... DONE!! ✊🏼✊🏼😄

[@fudogwhisperer3590]

$4500 plus the cost of die's? That's a tough bullet to bite when you're only doing a couple personal builds.

[@HumbleRoad]

Yes it is. But as I continue to build vans, this season; four of them at once, I decided the safety of having good consistent crimps was something I needed, without question. A poorly crimped lug with 300 Amps running through it can glow hot and cause a fire.

[@dand5829]

Milwaukee makes a 4/0 AWG cable stripper as part of their M18 line. Just hand over another 500 of your hard earned dollars and your wire stripping struggles will be a thing of the past.

[@kensoutham6828]

Cool, how about showing off the C&C 🙂 in action in another video?

[@HumbleRoad]

When we get it running, we will do many videos!

[@CanonNovice]

George, if you highly recommend a product, maybe you could set up a referral commission with a link in your description and post with EVERY video. It doesn't cost more for the buyer and you may get commission. Actually, as a viewer, I would appreciate this as whenever I decide to outfit a van I plan to use the same products you use. It would save me a lot of research time. I know Carey On Vagabond does this. What an excellent video on wire clamp installation.

[@CopyCatGarage]

One of these days George... I just want to spend some time with you one of these days and learn from you. You are so practical in your approach and yet still leave room to be creative. Teach me Obi-Wan Kenobi you're my only hope.

[@HumbleRoad]

Maybe one day!

[@mjremy2605]

You can start with your English first. YOU'RE not YOUR. Its a contraction for YOU ARE. YOUR indicates possession, as in YOUR ONLY HAT.

[@CopyCatGarage]

@@mjremy2605 I'm so glad you caught that. Thank you.

[@DanT1111]

The most important task with crimp tools is regularly inspection & calibration, either after a set period of time or quantity of crimps.

[@as6709]

I think the new, expanded workspace was needed for your vans AND to fit all your cool tools! 😎

[@vita-girl4345]

I have the same cheap Chinese tool. I find it works great for 4/0. I am just doing one van though. Still I love your giant Milwaukee commercials. Yes you should be sponsored.

[@baba_babaa2]

hahahah I just died laughing, "it's a success story waiting to happen"

[@tangwendeo]

Only quality material matches George’s quality work! (glad that I don’t need to wait for Sunday to see your “industrial art” videos)

[@IanSmithKSP]

Is 4/0 really necessary for a van? Seems a little excessive but I don’t know enough about batteries to say for sure.

[@HumbleRoad]

As I said, if you are using larger battery banks and large inverters then absolutely..

[@LilyWasHereMB]

The Graduate, one word: Plastics Humble Road, one word: Milwaukee

[@HenryOCarmichaelSmith]

Up the voltage, use smaller wire.

[@mjremy2605]

$4500 for a wire crimping tool? Highway robbery. Cheaper to fly to China, build a factory to make a cheaper clone. What an outrageous price tag for a hand held tool. No competition most likely. Very instructive to see these tools, however, and I'm learning so much. The devil's in the details!

[@jatorresrv]

Thanks for sharing. (The USA flag looks GREAT, thanks.)

[@anthonyg9787]

:) do you rent the tools out :P .... joking yes but that is a great tool.... I am almost at the point of doing wires in my van.... so this was a valuable video for me... but 4500 for that tool.... omg .... but your van shop is worth every penny.... thanks again for another short but great video

[@AntoineGrondin]

(1) Doing everything in 4/0 no matter the length and rating isn't smart. It's a waste of weight/resources and your customer's money. Use calculators, and aim for 3% voltage drop if you really want to be excessive about it. But 4/0 everything is just weird. (2) There's all sorts of ratcheting crimping tools that are ~150$ and will give you a fast, consistent crimp. "FTZ Correct Crimp" or Anchor's hex crimping tool work great.

[@HumbleRoad]

I may not have done an accurate explanation . I don’t use 4/0 everywhere and I do calculate every single wire run to the inch and allow for only 3% voltage drop.

[@AntoineGrondin]

@@HumbleRoad thanks for the clarification :)

[@GirdHerd]

At $4500 I'll stick with my $65 hydraulic crimper. Ha.

[@HumbleRoad]

I’m doing 3-5 vans a year simultaneously. So for me it makes sense. As I build vans for people, safety is my biggest concern.

[@GirdHerd]

@@HumbleRoad - Absolutely. If I were a professional van builder or RV solar installer I would make the investment too. BTW, George, you are, without a doubt, the best van builder I have ever seen (and I've watched many a build on KZbin).

[@allenahale1]

@@HumbleRoad The cost difference between your Milwaukee tool and the cheaper hydraulic crimper is minimal considering the lawyer fees you would have to pay if a client were to sue you for defective workmanship at some point in time. I just had an idea - I am not a lawyer but I have been involved in construction litigation, I recommend that you develop a procedures manual documenting the process that you utilize and require for the installation of items in your builds. These videos also should be archived as part of your procedures and QC manual. A little effort now to document will save you many dollars, time, and hopefully minimize litigation in the future.

[@NeoMK]

This is way too much work and struggle. You would never hack it in the marine industry. All you need to do is roll a razor knife around the jacket and slice down the middle and peel it off. Don't spin the knife around it, just roll it.

[@HumbleRoad]

Been there, done that. Hence the consistency of a dedicated tool.

[@TankToChest]

For only 4 big crimps I definitely can’t justify a Milwaukee tool.

[@HumbleRoad]

I do more than 4 crimps per van. As I said, I use this tool for 4/0 all the way down to 8AWG. Perfect consistent safe crimps.