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Old 16-06-2019, 17:07   #1
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Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

While my crimping with FTZ Power Lugs normally works like a charm, but I have started using #2 AWG cable and am having challenges. My FTZ power lugs and crimper come from Bay Marine Supply, so I believe they are both genuine, and the cable is Ancor.


The common power lugs available for #2 cable are marked #1-2. With #2 cable, it is definitely a loose fit before crimping. And after crimping with at the H-H (pink) setting, I can easily pull the cable out by hand. Even after re-crimping after rotating the lug 90 degrees, I can still wiggle out the cable.


2/0 cable in 2/0 power lugs, and #6 cable in #6 lugs both work fine.


Any ideas?





Thanks,


Allan.
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Old 16-06-2019, 17:15   #2
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

That doesn't look like #2 AWG cable. Looks like #6 or #4 at the most.

FT1 or FT2 is not a wire "size" but an insulation rating.
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Old 16-06-2019, 17:18   #3
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

Quote:
Originally Posted by ayates View Post
The common power lugs available for #2 cable are marked #1-2. With #2 cable, it is definitely a loose fit before crimping. And after crimping with at the H-H (pink) setting, I can easily pull the cable out by hand. Even after re-crimping after rotating the lug 90 degrees, I can still wiggle out the cable.


As you've stated, the ID for the cable is too large.

Either the lug is defective, with the ID too large, or the wire is defective, with the OD too small. Can the lug bore ID and the wire OD be measured?

The crimp tool might be wrong, but the fit should be snug, so my guess is not focusing on the tool yet.
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Old 16-06-2019, 17:23   #4
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

#2 uses different sizes depending on the different lug types, heavy-duty wall thickness etc

Try J-H (Brown).

If Alan is your supplier for everything give him a buzz in the morning, very responsive.
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Old 16-06-2019, 17:29   #5
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

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Originally Posted by john61ct View Post
#2 uses different sizes depending on the different lug types, heavy-duty wall thickness etc

Try J-H (Brown).
The Gray J-H lug is rated for 4AWG.
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Old 16-06-2019, 17:37   #6
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

I usually use Pacer rather than Ancor, from bestboatwire.com

the O.D. of their #2 is close to a 1/2"

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Old 16-06-2019, 17:38   #7
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

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Originally Posted by BlackHeron View Post
That doesn't look like #2 AWG cable. Looks like #6 or #4 at the most.
Fair question. The markings on the insulation do claim it to be #2 cable.


Thanks,

Allan.
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Old 16-06-2019, 17:38   #8
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

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The Gray J-H lug is rated for 4AWG.
Are you looking at the FTZ terminal catalog?
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Old 16-06-2019, 18:01   #9
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

Ancor specs

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Old 16-06-2019, 18:08   #10
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

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Originally Posted by wingless View Post
As you've stated, the ID for the cable is too large. Either the lug is defective, with the ID too large, or the wire is defective, with the OD too small. Can the lug bore ID and the wire OD be measured?

Wire OD (#2) is 5/16" and the power lug ID (#1-2) is 3/8"


Thanks,

Allan.
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Old 16-06-2019, 18:13   #11
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

markings match?

https://newcontent.westmarine.com/co...2018013010.jpg
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Old 16-06-2019, 18:36   #12
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

OP you're likely beyond these, but for others, this thread helped me
https://forums.sailboatowners.com/in...er-lug.189871/

This much older thread
https://forums.sailboatowners.com/in...cables.105674/

lead to MS' creating his most excellent two crimping HowTo's, now hosted on http://marinehowto.com/

https://marinehowto.com/making-your-own-battery-cables

https://marinehowto.com/marine-wire-termination
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Old 16-06-2019, 18:56   #13
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

What was your source for the Ancor wire? Link?
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Old 16-06-2019, 19:08   #14
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

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Originally Posted by john61ct View Post
What was your source for the Ancor wire? Link?
https://powerwerx.com/ancor-tinned-m...-battery-cable
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Old 16-06-2019, 19:52   #15
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

Yes I always thought them trustworthy.

Try a pulltest using the next setting down with the existing supplies, following MS' technique outlined in the links I posted.
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