Have you ever wanted to own an electric car? or have you ever wanted to drive a Porsche 911? I wanted both, so I decided to build one. This blog is here to document my journey as I convert a 2002 Porsche 911/996 Carrera 2 from a gas guzzler to a completely electric vehicle - not a hybrid!

Sunday, July 1, 2012

Building Cables

Today I bought some 2/0 lugs to terminate the 2/0 AWG welding wire used to hook the batteries controller and motor together.  Here are some pictures of the lugs, the lugs crimped to the wire, and the finished product complete with 1" heatshrink tubing to reduce the exposed metal.

 
This picture shows the rough size of 2.75inches long, about 3/4" in diameter.


 This picture shows one of the lugs crimped onto the 2/0 AWG welding cable.  I used a bench vise to crimp the opening on the lug. 

 This picture is one finished terminal including black heat shrink to protect the exposed copper area.
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3 comments:

  1. Power CablesJuly 17, 2012 at 8:57 PM

    Looks like a good, clean terminal. I’ve never heard of heatshrink tubing before though. What is that exactly? And how do you attach it?

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  2. Kurt LarsonJuly 18, 2012 at 11:02 AM

    Heatshrink tube is a plastic material that you place around your exposed metal joints and when heat is applied, the plastic shrinks to seal it up nicely. Here is an example of small heat shrink on a ring-terminal, fast forward to 1:30. http://www.youtube.com/watch?v=9Bcst2q9Fw4&feature=related This is a link to 1" diameter heatshrink that when it heats up shrinks down to 1/2" diameter. This is very close to the stuff I used.

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  3. Kurt LarsonJuly 18, 2012 at 11:02 AM

    Here is the 1" heatshrink link http://www.kta-ev.com/Magna_Heat_Shrink_Black_1_1_5_Long_p/5663-051b.htm

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