Bonding systems - 8AWG solid core to stranded wire connection

[Williwaw_]

I have a mid 80s Cal with a solid 8 AWG bonding/grounding system. I need to repair/replace a section. The original design has ring terminals crimped onto solid wire which is not suggested today as far as I can tell.

It also has 5 solid wire ring terminals bolted onto a keel bolt plate, usually under bilge water. I'd like to simplify this, and run the existing solid wire grounds to a bus bar, then run 1-2 proper stranded ground wires to the grounding plate. (This is not a lightning protection set up, its all 8AWG, and not properly isolated from what I can tell).

So, what is the best way to transition from solid core to stranded wire? Alternatively, are there any reliable methods to crimp solid core? I can solder.

Replacing the entire system is not possible or practical.

[s/v Jedi]

Originally Posted by Williwaw_

I have a mid 80s Cal with a solid 8 AWG bonding/grounding system. I need to repair/replace a section. The original design has ring terminals crimped onto solid wire which is not suggested today as far as I can tell.

It also has 5 solid wire ring terminals bolted onto a keel bolt plate, usually under bilge water. I'd like to simplify this, and run the existing solid wire grounds to a bus bar, then run 1-2 proper stranded ground wires to the grounding plate. (This is not a lightning protection set up, its all 8AWG, and not properly isolated from what I can tell).

So, what is the best way to transition from solid core to stranded wire? Alternatively, are there any reliable methods to crimp solid core? I can solder.

Replacing the entire system is not possible or practical.

Your plan for modification… is that based on a design or suggestions from an electrical engineer? I hear all kinds of alarm bells ringing and recommend you don’t make any modifications unless approved by a qualified engineer.

[Williwaw_]

OK, point taken.

To simplify, I need to replace a broken section of solid core 8AWG wire. I cannot access the originating point on the prop strut, so I'm stuck with needing to connect a bare copper wire to a grounding point that previously used a ring terminal attached to a stainless stud on a keel bolt plate.

What is the best way to make these connections - to a bare copper on one end, and to a 1/4" stud on the other that previously used a crimped on ring terminal?

[s/v Jedi]

Originally Posted by Williwaw_

OK, point taken.

To simplify, I need to replace a broken section of solid core 8AWG wire. I cannot access the originating point on the prop strut, so I'm stuck with needing to connect a bare copper wire to a grounding point that previously used a ring terminal attached to a stainless stud on a keel bolt plate.

What is the best way to make these connections - to a bare copper on one end, and to a 1/4" stud on the other that previously used a crimped on ring terminal?

You can buy connectors for grounding rods at the hardware store. The solid core goes into it as is and the stranded wire requires a crimped ferrule.

At the keel bolt you simply crimp a suitable ring terminal to the stranded cable. Use a closed lug and add dielectric grease before crimping. Use glue lined heat shrink to make it waterproof.

[Williwaw_]

Originally Posted by s/v Jedi

You can buy connectors for grounding rods at the hardware store. The solid core goes into it as is and the stranded wire requires a crimped ferrule.

At the keel bolt you simply crimp a suitable ring terminal to the stranded cable. Use a closed lug and add dielectric grease before crimping. Use glue lined heat shrink to make it waterproof.

This sounds exactly like what I'm after. Thank you. Do you have a name/link you could share? I'm not aware of such a solution.

Much appreciated.

[s/v Jedi]

Originally Posted by Williwaw_

This sounds exactly like what I'm after. Thank you. Do you have a name/link you could share? I'm not aware of such a solution.

Much appreciated.

There’s many types, here’s one: https://www.amazon.com/Connector-Cop.../dp/B0B1P15L43

Ferrules: https://www.amazon.com/Baomain-10-0m.../dp/B01I7X6FM8

you need a crimper that can handle the size: https://www.amazon.com/Hexagonal-Cri.../dp/B08TH75ZMR

[Williwaw_]

Extremely helpful, thank you. Certainly seems to be the best method given my situation, I had been searching for a while before posting.

[GordMay]

I'd use a tin plated split bolt connector, equal to Burndy 'Servit', type "KSU".
➥ https://www.hubbell.com/burndy/en/po...rs-split-bolts
➥https://www.hubbell.com/burndy/en/Pr...BBolts%253EKSU