How to crimp a lug (3 methods tested)

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In this video I go over how to crimp a solid copper style lug and compared 3 different methods... The fun part is at the end when I cut them open and we see whats going on inside.
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Опубликовано:

20 окт 2024

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Комментарии : 173

@HifiVega 5 лет назад

Check out my new Amazon storefront www.amazon.com/shop/hifivega

@chuckmiller5763 6 лет назад

I installed professionally for years back in late 80's - 90's. We used a pair of bolt cutters, grind out the cutter blades a little to match your crimp. Best crimps for big wire ever.

@HifiVega 6 лет назад

chuck miller I bet that’s why they make actual crimps in that style today lol.

@chuckmiller5763 6 лет назад

haha, maybe. We used a vise with a bolt sometimes too. But you needed 3 hands. Back then, not every car had a dash kit either. Subwoofer boxes were done with a scientific calculator. We were installing amps we could never afford.

@ljguy300 5 лет назад

@@chuckmiller5763 I got 3 hands a vice and bolt and need to crimp 0 gauge wire. How do I do it?

@chuckmiller5763 5 лет назад

@@ljguy300 open the vise, hold the bolt with your left hand, hold the connector with the wire in it with your right, with your center hand, close the vise with the bolt against the connector.

@Pilot_Tony 5 лет назад

No pro would do that! A hacker, maybe. Oh, wait I bet linemen use half ass tools too. It's why the power is so unstable? No, they use the right tools and the job last! Give me a break people, if you need this size wire then you need a crimp done right, and that means the right tools, same people that use their pliers as a hammer.

@dennissecor8092 2 года назад

Great video thank you, I used a hammer crimp tool, today, on one awg, I have an 01 Chevy express, that I am setting up, with 2 agm batteries, for off grid use, sobivstarted the wiring process, I also soldered, the lugs I made, and drilled a 3/8 hole in the end to connect to military spec, terminals, and in the rear, I want to get a DC to DC charger, with a 100 amp circuit breaker, first time I have ever done anything, like this, so I'm watching a lot of how to videos, thank you for sharing!

@russellburgan9023 5 лет назад

I've also used a punch in comparison to the first method tested. I now have a Temco hammer lug. I wanted a hydraulic crimper, but I couldn't justify it to myself... lol. Great video! Thanks man

@HifiVega 5 лет назад

I didn’t even consider a punch! Hammer crimps are still very good imo

@kevincharles1983 2 года назад

I've done the first method but with something shaped like the peice of metal you hit with the hammer on the second one,While laying on a piece of steel so there was no vibration. Turned out just like your the hammer crimp. That screwdriver was the main problem

@blakethesnake1555 Год назад

I’ve used a vice with a small nut on one side and it works decent. I still think those crimpers are the way to go. I do use dielectric grease in the lugs and coat the wire. Helps prevent any corrosion and makes a better connection

@MrMikesMondoVideo 4 года назад

How does anyone downvote this video? Good testing methodology... good examination of results... and links to the products that were tested. The only thing that would have made this video better is if the poster bought the tools for me.

@HifiVega 4 года назад

MrMikesMondoVideo thanks! I appreciate it

@matmichalke5734 3 года назад

I wonder if you tried a different diy method. My thought is on the screwdriver method, after hitting it a few times like the first step but then place the lug in your vise and place the screwdriver in the vise also and twist it as tight as you can

@normalicy 7 лет назад

I use that same hammer crimp almost daily on industrial batteries & forklifts. Never a failure. That said, I also solder the larger crimps pretty regularly as well and it also works great. The big difference between the hammer crimp and the hydraulic crimp to me is portability. You can't use the hammer crimp in a vehicle. But you can use the hydraulic.

@HifiVega 7 лет назад

The hammer crimp works great and was my go to before I got this hydraulic crimper. We have a really nice Burndy crimper for all our industrial and forklift batteries that we build at work.

@normalicy 7 лет назад

Oh, that would be a nice crimper to play with.

@HifiVega 7 лет назад

Mickey Pietrzak I'm going to do another video comparing other alternate methods and would love to use that one, but unfortunately my work is pretty strict about that kind of stuff.

@normalicy 7 лет назад

Well, if it's not a method that the average consumer can use, I'd probably skip it. That said, I suspect people would like to see a resistance measurement between soldered and crimped.

@boboconnor1403 5 лет назад

Good comparison. Was just looking to buy a hyd crimper and after watching your video you've convinced me it will be 50 bucks well spent...

@HifiVega 5 лет назад

Bob O'Connor definitely a good purchase. Thanks for watching!

@Gears.and.Gadgets 6 лет назад

Methods two and three are the best methods I've seen and used. You got a new subscriber.

@TheWardog1369 6 лет назад

Have you ever tried using vice grips in a couple different places? It was a method I had to use when I didn't have the hydrolic or hammer tools. Great video!

@coryholbrook4643 5 лет назад

The hammer lug crump tools are usually under $20 if that helps make any decision for anyone. Even the Harbor Freight hydraulic crimper is $65 so the price of those only goes up from there. The hand lever ones without the hydraulic assistance aren’t worth even looking at as you can’t create enough pressure to get an effective crimp

@Streetbikerider83 3 года назад

for years i have just filled the lug with solder and inserted the wire with molten solder inside. never had a problem with it. however I have an amp install job for a customer and he has open ended crimp terminals. so will finally after 15 years have to pick up the crimpers

@a64738 2 года назад

Solder is the best method of all, but crimping is faster and more easy to do so that is why all use that now...

@1lumpen 6 лет назад

I would've been interested to see the cables ohm'd out/continuity afterward to see if/how the methods differ in the cable's functionality.

@HifiVega 6 лет назад

Steve Matz that’s a good point and something I have been considering doing in a future video!

@wizardindustriesusa 4 года назад

It would just read 0 ohms lol

@a64738 2 года назад

Better test is to run a LOT of amps (like 300A+++) trough and see if they start to heat up...

@andrewrankine5412 2 года назад

The real test is putting the connections under the rated load for the cable size. That will tell you if it is any good or not. Using a thermal cameral will also help identiy if its a hot joint or not.

@puffinjuice 8 месяцев назад

Nice comparison video. Would have been nice to see some close up photos to get a better idea of which technique gave the best cold weld.

@myevilbanana 2 года назад

So is that hammer crimper something you made or that can be bought? Didn’t get a good look at it but seems pretty straightforward, might be able to use it with a small hydraulic press for better results. I’ve always done the screwdriver thing, I found on something that hard that won’t let the bottom of the lug mushroom out it hold a lot better.

@HifiVega 2 года назад

You can pick them up cheap and they work great amzn.to/3GvjV33

@MrSpanky473 7 лет назад

I've used the hammer method with a flat chisel many, many times. Always wanted a hydraulic crimper. Been using solder for a long time..its seems to yield good results. Good vid my audiophiliac bretheren.

@HifiVega 7 лет назад

Sinister I needed a chisel I bet it would have gotten better results! I should have tried solder as well I do solder all my open top lugs, but haven't ever tried on this style. There were a few other methods I wanted to try but alas I was low on lugs. Maybe I will do another one in the future with other methods suggested here in the comments.

@kylesonsalla7620 5 лет назад

You can buy that same hydraulic crimper from harbor freight for $50. I have one in my toolbox.

@anthonya1477 5 лет назад

$40 for a 16 ton hydraulic crimper from eBay, lots of dies too

@washingtonstatepicker3460 2 года назад

Thanks for the video! I love terminating wire, it fascinates me, so I appreciate your time and efforts!

@wizardindustriesusa 4 года назад

Now it's time to flow some current through them and monitor their temperature. The best connection should be the coolest under load.

@69elchupacabra69 4 года назад

Is that really the case? Wouldn't less resistance = more amperage for a given voltage = hotter?

@69elchupacabra69 4 года назад

@@jamesmeehan why is that? Won't connecting the leads of a battery with copper wire heat up more and faster than if they were connected by a 100 ohm resistor?

@louiemares1610 6 лет назад

This is great I am in the process of crimping quite a bit of wire I am new to your channel I've heard about you through Big D Wiz glad I did

@HifiVega 6 лет назад

Louie Villa Thanks for stopping by and checking it out!

@radical0720 3 года назад

that hammering screen effect is RAW!

@Gamleprofil 4 года назад

Thank you, I will be investing in a proper crimping tool now!

@christophermarshall5765 6 лет назад

One method which is even better, though it is not used much these days. This method is solder & crimp. This takes a bit of time. First, you heat the stripped wire, & soak it with solder. Next, you heat the terminal lug, & fill it with solder. While the lug is still hot, insert the wire. Keep it hot to keep the solder melted. Next, use a hydraulic crimper to crimp the terminal lug whilst it is hot. Allow it to cool. This will ensure strength & electrical conductivity.

@HifiVega 6 лет назад

Christopher Marshall this is definitely a method I need to put to the test! I’ve had many people ask about it... Thanks for watching and commenting, I do plan on doing his in a future video.

@Iceberg86300 2 года назад

Major problem with that is solder wicking. Any solder whatsoever in the wire that is outside of lug creates a massive stress concentration & that can cause issues unless it's a stationary piece of equipment completely free of vibrations. But I've done it. LOL. Too cheap to buy a crimper & it was on an around town car that was going to the crusher in a few years anyway. But no way I'd use it on something like a long haul vehicle that could leave you stranded out in east nowhere, or weld leads that are constantly being moved & stressed & whatnot. So you really just need to know your application & decide accordingly.

@Mr.SparkleOG 6 лет назад

Here from Big D Wiz!! Hope we can get you to 1000 subs!!! Excellent videos sir!!

@petetherealrelentless6542 5 месяцев назад

He got there! 😅

@petetherealrelentless6542 5 месяцев назад

Also good to remember that the hammer crimp device is only useful if you have a hard and stable surface to use in the process whereas the hydraulic crimper can be used in more scenarios.

@HifiVega 5 месяцев назад

Very good point

@petetherealrelentless6542 5 месяцев назад

@@HifiVega Great video btw.. I love videos like this.. going the extra mile to cut into the lug to really see whats going on inside rather than just tugging on it and moving on.

@harrywest6624 4 года назад

Thanks for the great info mate! I’m looking at getting a hydraulic crimper from eBay.. is yours any particular model that you would recommend?

@HifiVega 4 года назад

Mine is just a generic version. Probably the same as the rest of the cheap ones on eBay

@shawnsanderson3695 2 года назад

Thanks man that really helped me make a decision. Those hydraulic crips are real expensive right?

@HifiVega 2 года назад

You can pick up pair up for $46 amzn.to/3o2NSRb

@shawnsanderson3695 2 года назад

@@HifiVega Dude, thanks so much! Just what I needed. Already ordered them!

@HifiVega 2 года назад

@@shawnsanderson3695 no sweat homie

@mattheweburns 2 года назад

Had some trouble seeing the hammer message where exactly and how you were placing the screwdriver

@HifiVega 2 года назад

In a cross pattern right in the middle of the wire/lug section

@milvolts1 5 лет назад

I have done permant crimps with a little flux, solder and butane torch. Just clean copper so that the solder grabs. That's a no doubter crimp. Great video though. Easier to do either of those 3. In a stationary crimp senario screwdriver method would be enough. If that crimp is jumping around or vibrating. Do the hydraulic or solder. Thanks, take it easy...

@HifiVega 5 лет назад

mario sellet I’ve tested that method as well on this video ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-UMeGCQa-oCI.html

@milvolts1 5 лет назад

HifiVega, thanks for the link. Great minds think alike. The ugly one or all of them for that matter could of used a heatshrink. But then it would be to professional and scare off all the DIY'ERS. Peace brother

@gregblackburn4280 7 лет назад

This is a great video! I am preparing to make my 44 year old truck some new battery cables so let me ask you, with the odd crimp shape the hydraulic tool makes, would heat shrink still work over that?

@HifiVega 7 лет назад

GREG BLACKBURN Thanks! Yes heat shrink fits easily over the hydraulic crimp.

@gregblackburn4280 7 лет назад

Thanks.

@D.K81 6 лет назад

Great video sir! Very informative and descriptive!

@HifiVega 6 лет назад

D K Thank you!! And thanks for watching and commenting!

@RussTanner 4 года назад

Exactly what I needed to know. Thanks.

@gregblau8082 3 года назад

I’ve got a crimper like that hydraulic one but it doesn’t work well for 4 gauge or larger so I usually put them in the vise

@HifiVega 3 года назад

What dies are you using on the bigger gauges?

@gregblau8082 3 года назад

Mine has a solid jaw with 3 sizes and the biggest one would probably work but squishes out the sides like yours on 6 gauge so I didn’t want to ruin the lug trying it on 4

@HifiVega 3 года назад

@@gregblau8082 yeah you need a 65 die for most car audio 1/0 wire to get a nice crimp

@gregblau8082 3 года назад

I actually had to go to harbor freight and get a lug for 2 gauge welding cable because the 4 gauge I had didn’t fit the oversized wire.

@Backfire10 4 года назад

Can you show the results of the hydro method again. You did not reall show it

@joebelton2146 5 лет назад

I have been meaning to buy a hydroelectric crimper, But for now I use my trusty vise grips.its not as pretty but it is effective if you repeatedly crank them down.I also make my own lugs out of copper tubing.

@HifiVega 5 лет назад

Joe Belton I ended up doing that in a update to this video and it worked better than I anticipated for sure

@Hirokiji 5 лет назад

I don't know why anybody would solder 16mm2 cable??? That's what hydro crimpers are made for. Soldering wont produce an airless terminal in this application, but hydraulic crimping will produce that full ‘coldweld’ terminal. Anything else is inferior energy transmission and basically failure in ideal termination... For people watching this, heat shrink your terminals after crimping. Furthermore, I don't know why you didn't vice the lead when you pulled with your plier?

@HifiVega 5 лет назад

First Timer funny you should mention solder because I think I will do an update and put solder to the test. You’re right I should have used the vice, but sometimes you get wrapped up in the project and start doing without planning lol

@robertechols5066 6 лет назад

You should make a video on how to make copper lugs with 1/2 copper pipe ( 5 ft $9 ) shca $20 for 10 lugs and heat shrink , just a thought, cool dude

@HifiVega 6 лет назад

Robert Echols that’s actually a really good idea and something I might look into when I film a part 2 to this video.

@johnmilner7603 4 года назад

I would put the hammer crimper in a vice rather than hammering it several times. #2 is the best formation for the money.

@junkitlow 2 года назад

Very helpful thanks

@adrianaugustus2815 4 года назад

You didn't fancy the vice and bolt method?

@HifiVega 4 года назад

Not particularly

@fitzventure 4 года назад

Super helpful video. Thanks for putting this together.

@matthwy1 6 лет назад

Flathead or Philips screwdriver? Can't tell from the video.

@HifiVega 6 лет назад

matthwy1 flathead

@julzmax956 6 лет назад

I use vice grips when no other is available. I've never had a problem with using the vice grips.

@grzegorz16100 7 лет назад

That was what I was looking for!!! Thanks

@HifiVega 7 лет назад

Gregory May thanks for watching!

@jordancoleman8822 6 лет назад

Great vid!

@HifiVega 6 лет назад

Jordan Coleman thanks!

@dgam8261 6 лет назад

Big d sent me too. What cable cutters are those blue ones at the beginning of vid

@HifiVega 6 лет назад

Damian Gauna welcome aboard! Those are Blue Point pwc80a. I believe they’re made by some company (unknown to me) for many manufacturers including SK which sell them for half the price and are what I would recommend if you were considering purchasing them. Here’s a link to the SK version www.harryepstein.com/index.php/cutters-bolt-cable.html

@HifiVega 6 лет назад

Kelvin McGill 😂

@phazel 6 лет назад

From my work in the auto service field the Snap-on dealers sold Blue Point. Not sure if snap-on actually manufactures blue point or not though.

@cbradiomizfit7562 3 года назад

0:53 hammer it dooown brotha!!

@ArcadeDude44 7 лет назад

Awesome video, thanks

@HifiVega 7 лет назад

ArcadeDude44 Thank you and thanks for watching!

@jr1001jr 4 года назад

Is soldering the lug an option?

@HifiVega 4 года назад

jr1001jr yep ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-UMeGCQa-oCI.html

@jr1001jr 4 года назад

@@HifiVega I ender up watching your soldering-lug video about 45min after I made my initial comment... Loved your experiment, techniques, observations, and content. 👍👍

@adamvale8316 2 года назад

Could be your rock loading up with copper. Especially since it got harder to cut as you went. Or it could be a little of both.

@spearius9059 4 года назад

Bro. Excellent video.

@HifiVega 4 года назад

Roberto Cuestas thanks!

@jasonrambler4353 4 года назад

Incredibly well done..thank you!

@HifiVega 4 года назад

Jason Hambling thanks for watching

@Jboost412 3 года назад

I assume the thumbs downers...are the guys hitting the lug with a Thor hammer 🔨....2 grand on subwoofers..2 grand on amps...2500 on electrical support... not properly crimping your lugs priceless 😂

@ohioan7536 5 лет назад

Solid. Thank you for the info

@HifiVega 5 лет назад

Ohioan Thank you for taking the time to watch it!

@roncooke2188 5 лет назад

Use a different hammer that one is for pulling nails out

@HifiVega 5 лет назад

Had this hammer since I was a teenager and it does everything a hammer can do!

@96bansheepilot 3 года назад

@@HifiVega also that sheet of wood suspended in the air is absorbing all the force in the hammer blow. It should be hammered on the concrete ground or an anvil. No wonder the lug just easily pulled off.

@96bansheepilot 3 года назад

@@HifiVega also, keep in mind that all cameras have a minimum focusing distance....which means if the subject is too close to the lens, the lenses will not allow it to focus. Simply pull away from the lens a bit and the focusing system should latch on.

@joaquinjuarez5202 6 лет назад

I used to literally do that on the driveway using nothing but the hammer and the concrete on with it laid on..... I just went hulk smash, pancaking the terminal flat. I pull tested every connection and it werked, but it was ugly.

@realhoffman_3263 3 года назад

Spend $35 on a handcrimper and use it only once. Nahhhh.

@HifiVega 3 года назад

Get you a hammer crimp for $14

@kingmikefixit 8 дней назад

Nice

@walterandrews3077 Год назад

Don’t worry about those little wires sticking out. They’ll burn off!

@HifiVega Год назад

🔥

@RobHTech 3 года назад

You don't need to crimp it. Just get everything ready, heat up the lug, melt solder in it about 3/4 filled, then just put the wire in and let it cool. Just don't overheat it.

@HifiVega 3 года назад

I prefer a cold weld crimp, but… ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-UMeGCQa-oCI.html

@ah4800 2 месяца назад

Terrible way to solder. Nothing will wick into the wire.

@RobHTech 2 месяца назад

@@ah4800 hahaha. what a joke. Sure, if you do it your way it won't work

@ah4800 2 месяца назад

@RobHTech guess you've never heard of a cold solder joint. You're not supposed to glue it You're supposed to solder it. Like i said, solder travels to where the heat is naturally, you won't have any or very little solder between the wire strands.

@ah4800 2 месяца назад

Lets be serious here, the real joke is your soldering advice.

@ahmad7825 4 года назад

don't play with electrical cable by the wrong method...

@AdanmNoreiga 6 лет назад

Where here from the order of BigD WIZ...

@HifiVega 6 лет назад

Zack Noreiga thanks man! Welcome aboard! Big D is da man!

@NeoAH90 4 года назад

I use a center punch tool

@6pekXX 8 месяцев назад

Everything is out of focus! Did you even check it before upload mate?! 🤐

@garypriest7679 4 года назад

What if I used my vice

@thisisyaren Год назад

gotta say guys , wack lug sets are pretty nice

@chrisczarnik3439 8 месяцев назад

You did not show the results for long enough.

@jonessmith9281 5 лет назад

Dang no focus.

@HifiVega 5 лет назад

Jones Smith but a lot of hocus pocus!

@RooseveltJeffersonII 6 лет назад

Bigd sent me

@HifiVega 6 лет назад

Roosevelt Jefferson II he’s the man! And thanks for watching!

@orangecavi123 6 лет назад

Big d sent me

@HifiVega 6 лет назад

Todd Haworth he’s da man! Thanks for watching!

@ibleed1 6 лет назад

FOCUS

@iMakeItHappen96 5 лет назад

Nice but learn how to focus the camera

@nessabush1986 4 года назад

It's autofocus, he can't "learn how to focus." That's all in the camera.

@fresh55n9ne 5 лет назад

I use vise grip pliers to crimp these type of lugs it has worked for me

@HifiVega 5 лет назад

Fresh55n9ne that method worked better than I expected ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-cbdAK2SW6jM.html

@minnesnowda2510 3 года назад

Hydraulic crimp all the way

@HifiVega 3 года назад

🤟🏼

@Pilot_Tony 5 лет назад

Am an electrical engineer, nothing about any video is good from a connection point of view. Not one method here will hold the current that it is rated. High probability of fire. Don't do this, any of it!

@HifiVega 5 лет назад

Shoot me a link to your video that shows the proper way to connect a lug...

@Pilot_Tony 5 лет назад

@@HifiVega I don't have one. The correct method depends on the wire and terminal. Change either and the process must be changed. I worked for a major appliance manufacturer for many years and seen many crimps fail catastrophically. In some cases resulting in death from the fire which started at the bad termination. With currents as low as 14 amps. My point to all whom read is simple. Wire crimping must be done with the correct tooling based on the manufacturer of the terminal, the terminal must be chosen for the wire used, and lastly, the crimp hight must be in accordance with the terminal manufacturer. Or the results could be fatal. It's no joke, I have seen it.

@kinglangren 4 года назад

Anthony Alexander Macholtz I call bullshit , that hydraulic crimper was practically cold welded and the hammer crimper was sound also. Not one person who had done these methods in the field said otherwise in the comments.

@dirtmover123 3 года назад

@@Pilot_Tony In this case you're wrong. The hydraulic crimper is the correct tool for these lugs.

@Pilot_Tony 3 года назад

@@dirtmover123 no, I am not wrong. Please read my post again. What I said is that for ever terminal there is a matching die. The guy says he is not using the correct die. Over and under crimping cussed failures. That simple. Maybe the crimper it's self us fine and correct. But, per the video he is not using the correct die, therefore the termination is not to manufacture specifications. I saw this in China, they would almost perfectly copy the USA tooling, but very minor changes would cause failure. It depends on what is s acceptable for the application. But I guarantee that if the manufacture tool is not used, the termination will not meet the published specifications. Just ask any terminal vendor if you don't believe me.