Boxerworks.com

$50.

http://cgi.ebay.com/ebaymotors/BMW-R100 ... 23074af7d8

I too use welding cable. I would love to watch them crimp the terminals. Few really know how to do it correctly.

Duane Ausherman wrote:I too use welding cable. I would love to watch them crimp the terminals. Few really know how to do it correctly.

Yes, especially if we are talking of doing it the "MIL-SPEC" way as it always seemed to me at the time not all of it was 100% intuitive - indeed though proven time and time again to be superior.

Duane Ausherman wrote:I too use welding cable. I would love to watch them crimp the terminals. Few really know how to do it correctly.

I like Ken in Oklahoma's method he described above.

SteveD wrote:$50.

http://cgi.ebay.com/ebaymotors/BMW-R100 ... 23074af7d8

Wow, for fifty-beans! Man I am in the wrong line of work!

OK, so if one aspirin is good, twenty is better right? (Kidding...)

Airbear wrote:I've just added two extra earth cables to Brunhilde - gearbox to frame and frame to diode board - as recommended by GSPD* and others. The starter spins significantly faster, the alternator light goes out at lower revs, the horn is actually audible (instead of going 'beee erp' it goes 'BEEEEP' - first time I heard it I nearly fell off the bike). Everything is happier; even my cat is purring more often. The cable I used is not huge, it's rated at 20A. I'll be replacing the battery to starter cable next.

* Where the bloody hell is GSPD?

He's involved with a young Chickypoo. He'll be back!

Duane Ausherman wrote:I too use welding cable. I would love to watch them crimp the terminals. Few really know how to do it correctly.

Duane I have been making these for a couple of years now at WireWerkes and selling them at a reasonable price.
I have real nice industrial AMP crimper that has been customized for crimping the ends before soldering.
http://cgi.ebay.com/ebaymotors/ws/eBayI ... MEUSX%3AIT
I use a 4 gauge cable which is heavier than the BMW supplied 6 gauge and actually more flexible.
The terminals are small and compact like the original.

I can't see much from the photo. But I do have a few questions.

Is this a single, double, triple or quadruple crimp?
If two or more, which do you crimp first?
Does the terminal (lug) have an inspection window?
Do you clean the inside of the lug before inserting the cable?
You solder rather than use anti-oxyident grease in the crimp?
How do you keep the solder from wicking up the cable?

wirewrkr wrote:Duane I have been making these for a couple of years now at WireWerkes and selling them at a reasonable price.
I have real nice industrial AMP crimper that has been customized for crimping the ends before soldering.
http://cgi.ebay.com/ebaymotors/ws/eBayI ... MEUSX%3AIT
I use a 4 gauge cable which is heavier than the BMW supplied 6 gauge and actually more flexible.
The terminals are small and compact like the original.

That seems very expensive to me.

I'm away from the shop at this time, will be back on Wednesday and will post a picture (if I can) and you tell me what you do or don't like about the cables.
I use 1 single crimp before soldering, I don't clean the inside of the terminal, I don't see any need to, it's brand new, and the rosin flux cleans just fine.
No "inspection" hole in the terminal, again, why?
Years of experience soldering and knowing when to stop is how to control excessive wicking. I hand tin all my battery terminals. Mass production methods are different, some use pellets with weep holes for the excess solder. Is that the inspection hole you refer to?
My cables have a LIFETIME warranty if installed and maintained correctly.