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Old 17-07-2017, 10:36   #1
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Crimping 4 awg cable

We are getting ready to replace our original (i.e. 40 years old) DC panel with a new one, and this is likely the first of many questions.

We've purchased a Blue Sea DC panel (model 8377) and in speaking with their technical support it looks like we need 4AWG wire to run between the panel and the battery switch/batteries. The wire will have #10 or M5 ring terminals, but we need 5 feet and I can't find any premade to that length (nor anyone who will do it).

Any suggestions for where we can buy it? Otherwise, how do we crimp 4 awg cable? I'd rather not buy a $100+ tool which will only be used for this one project.

Thanks.
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Old 17-07-2017, 10:41   #2
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Re: Crimping 4 awg cable

Spicers Marina has everything you need to make the 5 foot 4AWG wire.

They will also make it to size for you as they have the Crimper tool on hand.
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Old 17-07-2017, 10:47   #3
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Re: Crimping 4 awg cable

Harbor Freight has a decent hydraulic crimper that you can pick up for around $40 if you decide to buy one. It is good for 0 - 14 awg
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Old 17-07-2017, 11:03   #4
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Re: Crimping 4 awg cable

You can special order crimped cables from genuinedealz.com for very cheap. I use that site to order everything electrical. It's alot cheaper than West Marine for connectors and wire.
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Old 17-07-2017, 11:09   #5
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Re: Crimping 4 awg cable

I think that genuinedealz.com will make anything you want, to order. I had enough to do (including the farm) that I went ahead and bought the FTZ 94284.

If you can't wait for mail order, The nearest West Marine has an Ancor hammer-crimper screwed down by their bulk wire screws. Clever of them, since you can ruin two terminals for every one that crimps correctly. You can just stand there and throw money away! But you get your cable on the spot.

More about battery cables here.
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Old 17-07-2017, 11:12   #6
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Re: Crimping 4 awg cable

If for some reason Spicer's can't do it, call a battery shop. In either Berlin or New Berlin, RAE battery could probably do it. They are the local Rolls Battery dealer. Between Stonington, (Dodson's), and every boat yard in Mystic, someone will do it.
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Old 17-07-2017, 11:23   #7
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Re: Crimping 4 awg cable

For a single wire, cost isn't going to be that big an issue IMHO, convenience and hassle are more important in the long run, as is using quality marine cable.

Our local West Marine isn't that expensive and uses a really nice hydraulic crimper. And ... you know they are using tinned marine grade cable.

A good battery supplier, or welding supplier can provide a fine crimped cable, probably for less money, but not likely a tinned cable.

I have had very good luck with a hammer crimper, only takes a little attention and care to get it right the first time.
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Old 17-07-2017, 11:26   #8
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Re: Crimping 4 awg cable

You can try Positive Battery in East Hartford thou I'm not sure they stock tinned wire. I know my Father in Law had some RV battery cables made there. If you get stuck and your near the Bristol CT area PM me and I can make one up for you.
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Old 18-07-2017, 09:08   #9
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Re: Crimping 4 awg cable

I purchased a hydraulic crimper off of ebay, Red Chinese model YUK-70 for about $40. I have used it over the past year to install about 50 terminals on 1/0 AWG, 8 AWG, and all down to 18 AWG. Installed 55 feet of 1/0 in various lengths and colors. The ebay 1/0 cost has been about $3 US per foot. I have not used it on stainless steel furrels but I fully expect it would work using proper dies. Wire also came off ebay but all was ancor marine. The terminals I purchase from Mouser Electronics, they are known as MOLEX battery terminals and higher quality and less expensive than most other terminals. Also recommend TE TAT-125-3/4-0-STK heat shrink for the 1/0 cable. Very thick, shrinks 50% and has hot release glue.
We do have 100's of dollars US tied up in electrical infrastructure . Our motto is "do it correctly, do it once, and be done"
Big Rig truck dealers, We have had good luck with International, also have wire and do crimping. BUT since they only work with large commercial equipment they have a limited assortment of supplies. I expect you could get the wire off ebay and take it to them.
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Old 18-07-2017, 09:09   #10
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Re: Crimping 4 awg cable

Try calling a semi truck parts dealer in your area.
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Old 18-07-2017, 09:18   #11
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Re: Crimping 4 awg cable

A Nico Press crimper works great on battery cable. West Marine usually has one set up on a bench if there is a WM up there.
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Old 18-07-2017, 10:24   #12
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Re: Crimping 4 awg cable

vice and three nails
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Old 18-07-2017, 15:47   #13
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Re: Crimping 4 awg cable

genuinedealz.com
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Old 18-07-2017, 19:43   #14
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Re: Crimping 4 awg cable

I use aluminum eyes with allen key set screws that lock it on to any wire. I've used them #0000 down to #14 AWG. They are the greatest even out in the weather 24/7 and they are reusable. I get them at any electrical wholesaler's.
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Old 18-07-2017, 21:02   #15
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Re: Crimping 4 awg cable

Crimping tools can be had for around $30.

https://www.amazon.com/dp/B017S9EINA..._GLTBzb0DFKCA4
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