Wednesday, March 05th, 2008 | Author:

Now, I’ve been told by reliable sources that soldering lugs onto battery cables is actually unnecessary. It’s been said that crimping really is “good enough.” I wish I could agree because it would save us time and a little bit of money on our systems, unfortunately I can’t. When we install a renewable energy system, the goal is that the system will remain working for at least the lifetime of the purchaser. Although we know batteries must be replaced eventually, nothing else in the system should, barring improper installation, defects or abuse. This lifetime goal includes the battery cables. When you only crimp lugs to battery cables you leave room for corrosion to snuggle in, build up and eventually create a point of resistance. This corrosive buildup over time can loosen the crimp by eating away at the cable or lug and may actually allow the cable to be pulled out of the lug or worse. Surely we all have made plenty of bad crimps, some we knew about and some we didn’t, soldering eliminates any question of a bad crimp. When you solder the lug to the cable, you make them “one” or as close to “one” as reasonably possible. There should be no argument that soldered connections are better than crimped connections. Ok, so is it cost effective? If you count the cost of the solder rig needed then maybe not, but our prices on custom length, crimped and soldered cables with heavy duty lugs is right in line with popular catalog company prices on generic length cable with low budget crimped lugs. They’re certainly cost effective in these terms.

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