Positive Battery Cable Connector
Thread Starter
Burning Brakes
Joined: Jun 2000
Posts: 892
Likes: 0
From: GA
Positive Battery Cable Connector
Hi Everyone,
I started the 70 this weekend after a VERY long hiatus. (work kids..etc..)
The starter started grinding... again... While unbolting the starter, I noticed the starter bracket to the engine block was VERY loose...
Anyway... I turned quickly... slammed my head on the frame rail and let go of the starter while the positive cable was still connected to the starter.. (not the battery). The connector BROKE
.
This is a factory new replace I installed sometime ago while completing body off. (still on 10miles on the car...) I know what it takes replace cable sooo..... Can I get a new end and crimp and/or solder new one? I broke right at the bend...
I love my Corvette but this car really likes to test my patience and love...
Anthony
I started the 70 this weekend after a VERY long hiatus. (work kids..etc..)
The starter started grinding... again... While unbolting the starter, I noticed the starter bracket to the engine block was VERY loose...
Anyway... I turned quickly... slammed my head on the frame rail and let go of the starter while the positive cable was still connected to the starter.. (not the battery). The connector BROKE
.This is a factory new replace I installed sometime ago while completing body off. (still on 10miles on the car...) I know what it takes replace cable sooo..... Can I get a new end and crimp and/or solder new one? I broke right at the bend...
I love my Corvette but this car really likes to test my patience and love...
Anthony
Burning Brakes
Joined: Jul 2004
Posts: 783
Likes: 38
From: Mankato Mn
I'm pretty sure you can. I've replaced ends on battery cables (not that one however) You should be able to find one at an electrical or welding supply. They should have solder or crimp-on type. You will need to know the size of the cable.(4,3,2) I believe that one needs to be bent. You can do that in a vise. Unless you have access to the right crimper I would solder it. Clean the wire & the inside of the lug & use a small torch. It's just like sweating a copper pipe fitting.
Thread Starter
Burning Brakes
Joined: Jun 2000
Posts: 892
Likes: 0
From: GA
I'm pretty sure you can. I've replaced ends on battery cables (not that one however) You should be able to find one at an electrical or welding supply. They should have solder or crimp-on type. You will need to know the size of the cable.(4,3,2) I believe that one needs to be bent. You can do that in a vise. Unless you have access to the right crimper I would solder it. Clean the wire & the inside of the lug & use a small torch. It's just like sweating a copper pipe fitting.
I was going with your advice and started to look at the issue. I really did not have enough slack on the cable, so I unbolted the first hold down. Then I realized.... Hey this is kinda easy. The threads were spotless on all six bolts...and the Muncie allowed enough room. Now the cable is out. But, do I still solder or just replace now.... What vendor carries exact positive battery cable? I know a lot are different.
Race Director
Joined: Mar 2006
Posts: 14,112
Likes: 28
From: Florida
Better to just make your own cables, will last a lifetime and possible solve some potential no start problems. Everything available at a welding supply. Crimp and then sweat solder.
The oem wire is copper clad aluminum and some replacements are no better. 1st and 2nd pic are oem and last 2 are copper welding cable
The oem wire is copper clad aluminum and some replacements are no better. 1st and 2nd pic are oem and last 2 are copper welding cable
Thread Starter
Burning Brakes
Joined: Jun 2000
Posts: 892
Likes: 0
From: GA
Thanks guys. The grommet for the cable is still brand new and I have it out of the car too. A few more questions.
How do I crimp the end like the picture posted? That wire gauge looks thick.
I think this might be a dumb question, but what do I use the sweat the connector(s)?
Lastly, what about the battery terminal side... do they make a connector that can be soldered as well?
I don't have much experience with this stuff... although you guys make it sound very easy. Just want to make sure I get the right stuff.
How do I crimp the end like the picture posted? That wire gauge looks thick.
I think this might be a dumb question, but what do I use the sweat the connector(s)?
Lastly, what about the battery terminal side... do they make a connector that can be soldered as well?
I don't have much experience with this stuff... although you guys make it sound very easy. Just want to make sure I get the right stuff.
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,117
From: Crossville TN
OK.... The connector can only be properly crimped in a press with the appropriate tool. You can 'sweat' solder the wire end into the connector using a propane (bottle) torch, some flux, and some solder. Just cut off the necessary insulation at the end, brush flux over the open wire area [don't be stingey], place the connector in a vise with open end "up"...also put some pieces of wood on either side of the connector lug so that the heat doesn't dissipate through the vise..., put the wire into the connector, wrap a piece of water-soaked cloth around the wire insulation near the end of the wire (this will keep the heat from melting the insulation). Now just put the torch flame on the outer body of the connector while inserting the end of the rolled out solder into the top of the connector. When the solder starts to melt, just keep feeding more solder into the connector until it gets fairly full. Then pull the heat away and let it cool. It's best not to spray/pour water on the hot lug, as it could damage the joint and/or spray steam at you; but keep a glass of water and/or a fire extinguisher handy...just in case.
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Top 10 Corvette Engines RANKED by Peak Torque (70+ Years of Muscle!)
Joe Kucinski
Corvette ZR1X Will Be Pacing the Indy 500, And Could Probably Race, Too!
Verdad Gallardo
Top 10 Corvettes Coming to Mecum Indy 2026!
Brett Foote
Top 10 C9 Corvette MUST-HAVES to Fix These C8 Generation Flaws!
Michael S. Palmer
Le Mans Master
Joined: Jun 2006
Posts: 6,399
Likes: 1,226
From: Tampa Florida
Thanks guys. The grommet for the cable is still brand new and I have it out of the car too. A few more questions.
How do I crimp the end like the picture posted? That wire gauge looks thick.
I think this might be a dumb question, but what do I use the sweat the connector(s)?
Lastly, what about the battery terminal side... do they make a connector that can be soldered as well?
I don't have much experience with this stuff... although you guys make it sound very easy. Just want to make sure I get the right stuff.
How do I crimp the end like the picture posted? That wire gauge looks thick.
I think this might be a dumb question, but what do I use the sweat the connector(s)?
Lastly, what about the battery terminal side... do they make a connector that can be soldered as well?
I don't have much experience with this stuff... although you guys make it sound very easy. Just want to make sure I get the right stuff.
I'm an old Western Electric/AT&T guy...I use a Thomas & Betts manual power crimper for crimping lugs, splices, etc.
Race Director
Joined: Mar 2006
Posts: 14,112
Likes: 28
From: Florida
You should crimp it before you solder.
Get the proper size lug for the wire, insert the fluxed cable end into the lug, lay it on a soft 2x4 or even rolled up carpeting and use a cold chisel and hammer longitudinally in the center to crimp it. It should turn out like the pic.
I put the same lugs on each end and use an adapter or marine battery if it is top post. These lugs will just bolt on a side post battery.
Get the proper size lug for the wire, insert the fluxed cable end into the lug, lay it on a soft 2x4 or even rolled up carpeting and use a cold chisel and hammer longitudinally in the center to crimp it. It should turn out like the pic.
I put the same lugs on each end and use an adapter or marine battery if it is top post. These lugs will just bolt on a side post battery.
Thread Starter
Burning Brakes
Joined: Jun 2000
Posts: 892
Likes: 0
From: GA
Is it that obvious... my group works via keyboard?
You should crimp it before you solder.
Get the proper size lug for the wire, insert the fluxed cable end into the lug, lay it on a soft 2x4 or even rolled up carpeting and use a cold chisel and hammer longitudinally in the center to crimp it. It should turn out like the pic.
I put the same lugs on each end and use an adapter or marine battery if it is top post. These lugs will just bolt on a side post battery.
Get the proper size lug for the wire, insert the fluxed cable end into the lug, lay it on a soft 2x4 or even rolled up carpeting and use a cold chisel and hammer longitudinally in the center to crimp it. It should turn out like the pic.
I put the same lugs on each end and use an adapter or marine battery if it is top post. These lugs will just bolt on a side post battery.
What is the gauge of factory cable? I am wondering if I need to buy bigger cable clamps as well...
oppss.. I see it was posted factory is 2...
Last edited by Mr.Gearhead; Sep 9, 2009 at 12:39 PM.
Burning Brakes
Joined: Sep 2007
Posts: 802
Likes: 69
From: Tulsa Ok
Hi, I'm lucky enough to work for a Battery Cycler Manufacturer...We sell equipment to battery manufacturers....I always make new positive and negative cables for my vettes....#2 welding cable is great for it... Always works great.... Crimp with the right tool works great but the tools are expensive...the chisel and hammer method works as well.... i heatshrink around the terminal to give a clean look....
Good luck!
Good luck!
Le Mans Master
Joined: Aug 2006
Posts: 7,425
Likes: 1,559
From: mount holly NC
2025 c3 ('74-'82) of the Year Finalist - Unmodified
2019 C3 of Year Finalist (appearance mods)
I am a welder repair technician, a proper crimp with the correct lug will work just fine, but to keep the customer happy I always soldered the connections. #2 copper will work fine and pretty much last forever on your vette.
PG.
PG.
