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Dave9111 · 25-06-2019, 20:44

I'll try and be gentle, but the problem is, that you have crappy lugs.

I've never seen a quality lug that was rated for 1-2 gauge wire. There is quite a difference between 1 and 2 gauge wire. You won't be able to get a good crimp that you will want to trust with such a lug. You need better lugs. You want a lug that slides over the conductor without excessive slop. When it crimps, it shouldn't flatten out because the lug is 3/4 full.

Check out this website. This is their Burndy lug chart - note that they have a different lug for 1 gauge vs 2 gauge.

https://wesbellwireandcable.com/burndy.html
I have purchased thousands of dollars worth of wire from this company. They have good service.

If you want some super nice cable for your boat, check out their DLO (Diesel Locomotive ) cable. Its like welding cable on steroids. Rated for 2000 volts with fine stranding and tinned conductors. Its not cheap but its really nice and flexible. I think they sell it by the foot as well.