How to Make Battery Cables

Building your own battery cables can save money and ensure a durable connection for your vehicle, boat, or other machinery. Follow these step-by-step instructions to create custom battery cables that fit your exact needs.

Parts Overview

1. Grabbing Supplies
2. Preparing the Cables
3. Attaching the Terminal Lugs
4. Attaching the Terminals

Part 1: Grabbing Supplies

1. Inspect Your Battery and Connections
   • Check for rust, corrosion, or damaged cables. Identify which cables need replacement by removing any faulty ones.
2. Determine Cable Gauge and Type
   • Locate the gauge size printed on your existing cable (e.g., “2/0 AWG”). Ensure your replacement cable and terminals match this size.
   • Use untreated copper wire for dry applications (cars, tractors) and tinned wire for wet applications (boats, jet skis).
3. Collect Required Materials
   • Cable (copper or tinned, depending on use).
   • Terminals and Terminal Lugs (matching gauge).
   • Non-acidic solder wire (e.g., rosin core).
   • Rosin flux paste or fluid.
   • Shrinkable sheathing (cut into four 4-6″ pieces).
4. Tools Needed
   • Cable cutters.
   • Heat source (butane torch recommended).
   • Crimping tool or flat nail punch and hammer.
   • Wire cutters.

Part 2: Preparing the Cables

1. Cut the Cable
   • Use heavy-duty cable cutters for smooth, clean cuts. Avoid saws or knives that can create jagged ends.
2. Strip the Insulation
   • Remove about 1 inch of rubber housing from each cable end to expose the wire.
3. Remove Loose Strands
   • Check for and remove any stray strands of wire to ensure a neat connection.
4. Add Shrink Tubing
   • Slide two pieces of shrink tubing onto each cable, positioning them away from the exposed ends.

Part 3: Attaching the Terminal Lugs

1. Apply Flux Paste
   • Coat the inside of the terminal lug and the exposed wire ends with rosin flux paste to improve conductivity.
2. Insert the Cable into the Terminal Lug
   • Push the cable into the lug as far as it will go.
3. Crimp the Terminal Lug
   • Use a crimping tool or hammer with a flat nail punch to secure the lug to the wire. Crimp on both sides for a tight fit.
4. Heat and Solder the Connection
   • Use a torch to heat the lug until the flux boils, then solder the connection where the cable meets the terminal lug.
5. Shrink the Tubing
   • Slide the shrink tubing up to cover the exposed connection. Use your heat source to shrink it tightly around the cable and lug.

Part 4: Attaching the Terminals

1. Secure the Terminal in a Vice
   • Clamp the terminal securely in a vice with the open end facing up.
2. Apply Flux Paste
   • Coat the inside of the terminal and the exposed cable ends with flux paste.
3. Heat the Terminal
   • Use a torch to heat the terminal until the flux boils. Preheat the cable for 12-15 seconds as well.
4. Insert the Cable
   • Push the preheated cable into the terminal.
5. Solder the Connection
   • Solder the point where the terminal and wire meet to ensure a solid connection.
6. Clean Up Loose Strands
   • Use wire cutters to trim any loose or exposed strands.
7. Apply Shrink Tubing
   • Slide the shrink tubing into place and heat it until it snugly covers the exposed connection.

Tips

• Patience Pays Off: Taking the time to make clean cuts and solder carefully will result in longer-lasting cables.
• Use Proper Tools: Investing in high-quality tools ensures better results and saves time.

Warnings

• Work Safely: Always wear gloves and goggles when working with high heat and electricity.
• Dispose of Materials Properly: Follow local regulations for disposing of old cables, solder, and flux.

By following these steps, you can create durable, high-quality battery cables for your machine or vehicle.