2nd Gen Non-Engine/Transmission My Battery Cable Experiment....

[mwilson]

Well, the time had come and gone for the '97 to get some new battery cables.

The previous owner (hack?) had cut the ends off and used emergency terminal ends. They were green, white and other nasty colors.



I had been searching for a better way to do this without buying new factory ones or trying to scab several wires onto the left hand positive end.



So I found a terminal block that Cooper/Bussman makes and ordered one.



Here are some pics, it is not the typical work that I do but had limited time yesterday so here it is in basic form. I will got at it again in a few weeks when I have time.



I can tell you it turns over twice as fast as it did and the lights are brighter. Also running a tad above 14 volts now rather than the 13. 5 volts before.



Please offer any comments or suggestions, I can take it...



Mike.

 

[NIsaacs]

Nice job on the ends and shrink wrap. Are those solder type ends? When I changed out my original batteries about 6 years ago, I used those identical Car Quest batteries. They were horrible on my ends, for a maintainance free battery. I blame it on the close proximity of the vent caps. The ends were just like new when I changed them.



Then about a year ago I changed them again and used a whole can of spray cleaner on the ends and cleaned them up fairly good. I also bought batteries with "no" vent caps, they have small vent tubes. Notice on the lower right and upper right a small vent tube. Never mind the "Rat Turds" :-laf So far they are doing much better. When I changed them this time I ordered new Dodge hold downs because the old ones were toast. While I was waiting on the parts I installed just one battery to get by and noticed with one battery the truck did not seem to perform as well. Slow starts when warm and just several little bugs as I drove it. These trucks seem to need two good batteries.



PS: Where are your hold downs?



Nick

 

[Nyoest]

Looks good! I did the same thing last fall and am so proud of the pretty terminals I won't give jump starts!

Get some corrosion preventer on there ASAP. I hate the stuff but it's the only way to stay away from all those pretty colors.

 

[mwilson]

Thanks, guys!!!



I will get back to it soon and finish the clean-up and coating of the terminals.



I had been tossing the junction block idea around for a while, I had to do something quick as I noticed it just wasn't turning over as well as it should this week so I dove into it yesterday.



I had promised to meet my wife at our daughters house for supper at 5. 30pm.

At 3. 45pm I am still cutting cable and 60 miles away.

Needless to say, I was throwing things together. If it reached it went on the stud, if it was too long it still went on the stud..... :-laf



It was my first attempt using solder slugs which are just the cats *** from what I can see. After a couple uses I was confident enough to use them on existing cables still attached to the truck. Just stand the terminal up right in the battery box using a pair of vice-grips and heat it right there.

Works slick. I am now a fan!!



Showed them to the Shop Foreman and told him that we should throw the cable crimpers out into the woods and change to the slugs, he agrees.

Much better results and once you put the heat shrink on them they are sealed up as well as the OEM cables.



I do have hold downs, but the same ninny that hacked the cables up also broke the slots in the boxes where the clip nuts go so I have to repair the damage first. They sit still but I would not dare to plow or go off road with it until they are properly held down.



I will get them buckled in soon.



Mike.

 

[seafish]

All those look really good!!!!



FYI--been using plain old vaseline as "battery terminal corrosion protector" for years. Works GREAT, and MUCH cheaper then any "special coating".



FYI #2-- Vaseline ALSO works as a dust seal if you spread a thin layer on the air box cover edge or on the TOP part of the air filter edge that contacts the air box cover.

I also use it to "dust seal" the fuse box of any engine compartment located fuse box simply by using a q tip to spread some on the edge of the cover that contacts the box. Obviously, it does NOT take much... I have had the same small jar of vaseline in my garage for 20 years now. ALSO, you don't have to do it every time, as the vaseline reseals to itself when you tighten down the air box or fuse box cover.



An OLD timer taught me about using vaseline on the battery terminals to prevent corrosion... I figured out the the other tricks at some point when I was inspecting my air filter (and fuse box) after putting vaseline on some new battery terminals.

 

[ed9824v]

we went with crimp connectors and these hummvee battery terminals with double wall adhesive shrink.



#ad




#ad




#ad




so far now corrosion and working fine happened to pick up the crimper at the swapmeet for $5

 

[mwilson]

That looks good as well!!!



I was playing with the terminal blocks as it would make it far easier to add the jumper cable socket, electric plow feed, winch feed, etc...



I think now I will use a 3/0 3/8" lug from the starter and solder the small wires into that same lug. That would eliminate 4 ring terminal connections.



Still working this around in the old noggin.



The solder slugs may generate some interest on here as all you need is a propane torch to assemble them and then to warm the shrink tubing.



Seafish, I use the Vasoline on the terminals as well. I used to use chassis grease but it was messy if you wanted to boost someone so I switched over a few years back. It seals the terminals very well.



Mike.

 

[Bill Stockard]

Seafish, I use the Vasoline on the terminals as well. I used to use chassis grease but it was messy if you wanted to boost someone so I switched over a few years back. It seals the terminals very well.



Mike.

Yep, I've used Vasoline for years too. My late father, and electrical engineer, designed, worked with, and on electromechanical control systems in his customer's industrial plants in the 40s, 50s, and 60s, kept a jar of it in his tool box and taught me that Vasoline was the best thing to use to protect terminals.



Speaking of soldering, his employer, Leeds & Northrup, would fire any one if they found acid core solder in their tool box... a no-no for electrical work.



Bill

 

[JKosten]

I too have done all new cables and ends.

The first thing that I have heard some people voice concern about in regards to soldier ends it that you are completely depending on a chemical/metal bond. If that cable heats up enough, the soldier will loosen and the cable drops out. Probably not an issue, but the possibility is out there, and just think about Murphy's law... I choose to mechanically crimp and then soldier all the ends on my cables. The easiest way is with a battery cable crimper, but since I do not have one at home I used my 20ton shop press and a punch centered on the lug. This puts a nice crimp down the middle, parallel to the cable. Then I went back and soldiered each connection and heat shrinked. I am not worried about any of the cables I made worked loose from vibration or heat now.

Also what is the part number for that terminal block and what is it rated for?

The cables after I was done
#ad

 

[mwilson]

Also what is the part number for that terminal block and what is it rated for?

Here is the link, it is almost impossible to find in the website.



http://www.cooperindustries.com/con.../BUS_Tns_Single_Stud_Type_Junction_Blocks.pdf



Very stout little critter. The Maine winter will tell if it is stout enough. .



Mike.

 

[HHhuntitall]

Looks good Mike. I'm gonna have to voice my concerns about the solder heat-releasing. I've seen it done, especially when the grid heaters go to work, if they're pulling through the same terminals as the starter..... I'd suggest leaving them in their own connectors, just for precautionary measures. I redo all kinds of things around here. I've used those like you did, crimp on, emergency clamp on, and even bought new when I feel like it. I personally like the crimp ons. Unfortunately, I've had to crank on some of these more than I like, especially the old LTA-10s, and I've melted some of my solder on terminals... ... . ticked me off, too!! They look so nice!!! And if you ever get a short, they don't fair too well, either. You might not have an issue up North where it's cooler, and I'm sure keeping the corrosion out of them is biggest thing to keeping them working like new. I use whatever corrosion inhibitor I can get; grease, spray on, paint..... whatever is handy. I try to keep terminal protectant in my truck, though. And shrink wrap is one of the best inventions ever!!!



I'm torn on the terminal block... . I like the idea of the satellite link from the battery, but I also see it being a problem if you blow a tire or drop a wrench... ..... hmmmm. If it had a little better cover on it, that'd be the ticket!! I wonder if you could get one of the rubber Freightliner terminal caps to go on it? Those red ones that snap on to the rubber base, with a tether to keep 'em from taking a nature hike on the interstate? THAT would keep me from welding a good Snap-On wrench to my hydraboost!!! :-laf Have to be an octopus looking thing, though... ... that's a lot of wires!! Maybe a nylon or plastic box, like a winch solenoid cover? I'm thinkin' out loud, here..... still looks really nice and clean.

 

[Nyoest]

Maybe a terminal box like in trailer lights would work for multiple taps?

 

[HHhuntitall]

Something like this would save my arse!!(and my hydraboost ABS lines!!! :-laf)



^* BATTERY TERMINAL COVERS RED (Set of 4) boat | eBay



(but then, you're probably not as reckless as I am, so it's not an issue for you!! )

 

[WilsonF]

I get my remote terminals from the wreaking yard the older Chevy pick-up have them, even have a built in guard on them.

Floyd

 

[mwilson]

Thanks again for all of the ideas and input, I have spent hours thinking about it and finally figured I would take a rough stab at it.



I plan to install some protection over the post, was thinking of a chunk of heater hose or something of that nature so that I can't get the fuel filter canister stuck between the hydro boost lines and the hot terminal... ...



I will get back to this tonight, am currently knocking back a

"Honey Do" list that would topple an ordinary man. .



Five new outlets plus a new phone jack in the kitchen, new propane feed line for the Vermont Castings Stove and work at replacing all trim at floor to wall.



And yes, my AC wiring looks much cleaner than that inner fender on the truck does right now...



Mike.

 

[firefighter_2000]

I have found that by switching to the Optima batteries, I have ZERO corrosion come up on my batteries. Have had them on for a couple of years now, and still none. I guess them being sealed prevents the "battery gas" from getting out and causing problems.

Craig

 

[HEMI®Dart]

I have found that by switching to the Optima batteries, I have ZERO corrosion come up on my batteries. Have had them on for a couple of years now, and still none. I guess them being sealed prevents the "battery gas" from getting out and causing problems.

Craig

Same here!

 

[HEMI®Dart]

Here is the link, it is almost impossible to find in the website.



http://www.cooperindustries.com/con.../BUS_Tns_Single_Stud_Type_Junction_Blocks.pdf



Very stout little critter. The Maine winter will tell if it is stout enough. .



Mike.

Mike what's the p/n you bought?

 

[mwilson]

Mike what's the p/n you bought?

Bill, I bought the JB3816 2 (Black) and JB3816 3 (Red). All the way to the bottom of the page.



Mike.

 

[guldam]

When I was wiring up my home built boat I had a ton of cables to make up for my dual battery set up with switch and two outboards. My buddy came over with his super duty crimpers, and then we both went to West Marine, to get the wire, and the ends. They actually had the crimping tool there for free use in the store.



So measure your cables, find the lowest price per foot on these cables on the web, and print out the page of the site you found them on, and take it with you to West Marine. They'll match your price, and lend you the tool to make up your own cables.



We just took the wire and ends home, and my buddy crimped them and then put on heavy duty shrink tubing.



GulDam