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Date: 10 June 2018. Proper Attachment of a Terminal End.


During the 32-volt battery bank troubleshooting and eventual replacement there were problems with two 4-gauge wires. One went on the #8 battery terminal. That positive wire end piece had broken. I replaced it. There is a right way to put on a new terminal end. Here's how to do it correctly.

This is the PROBLEM ↓ connection. It was loose when I removed the cable from the battery stud.

Tools, ready for the task at hand:


When working anywhere, it is important to observe. As I was taking the wires off the batteries I saw one cable end that was loose. The loop had broken. This is unacceptable. It needed replacement.

I kept notes on where the cables belonged. First I made a schematic of what was there.

Then, as cables were removed I wire tied them. All were numbered so I could replace them properly.

Note that both the nut and lock washer were wire tied to each end. That way they wouldn't get lost.

The direction you squeeze matters. Clamp so that the squished part is on the same plane as the business end of your fitting. In other words, make it flat. That is the best way to get a good tight connection that won't fail.

First I slid a 2" piece of heat shrink onto the 4-gauge wire. The new terminal end slid on easily too.

Then I began the process of tightening the terminal end to the 4-gauge wire.

Please note that were I professional I would have a pair of real crimpers for this task. As a budget boater I have learned to use vise grips for crimping everything up to 4 gauge. Larger gauge, sizes 2, 1, 0 (zero) and 00 (pronounced double aught) will not work with vise grips, however size 4 and smaller wires do just fine for me.

I could not live without my vise grips.
Buy the brand name version. Below, affiliate link:

Vise-Grip 5-10WR Curved Jaw Locking Pliers with Wire Cutter

First I squeeze to get the flatness started. Opening the tool, I continue to tighten the screw on the vise grip's handle 1/4 turn with each compression. This is NOT the way a pro would do it. He'd have a real crimper.

I find this method works well for me.

This is part of the group that belongs on battery post #8.

Note that the PLUS SIGN by the positive terminal was painted over with red nail polish. It is now easier to see.

After the terminal end was attached, I used the lighter on the heat shrink.
Then it was a simple matter to install this cable onto Battery Terminal #8.

More tomorrow. A subscriber is installing a new battery bank and I wanted to be sure he knew the direction to crimp on the ends. It really is important to do this part correctly.

Some ends such as those for smaller gauge wires have a split in the middle. When you squeeze the wrong way the wires can escape. That is never a good thing.

Now don't forget that if you need to buy parts please be sure to use my link. There is one found at the top of every page. It really does help me and costs you nothing. I've got a Wish List on Amazon too... trying to save up for a new Paperwhite or maybe one of those 10" in 64G Fire's. My Paperwhite is not always taking a charge.

End blatant plug.

My friend Donny on S/V Spirit. Keeping the memories alive... sailing's wonderful.

I have been having a lot of fun out here. The goal is to post shorter pieces more frequently. Still when given a choice between writing which I do enjoy and reading, especially when a favorite author has a bunch of books on sale... Well, suffice it to say if you have stock in Harlequin's Betty Neels books found on Amazon, you're getting rich!

Back to my Kindle. (waves from the forward berth)

Thanks for reading.

Are you a fan of vise grips? I use them for practically everything.
Do you have a legitimate pair of crimpers for wire work?



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