Soldering end of welding cable

Try heating up the ends and not just the cable. That's what I did. Worked very well. I also used my small portable oxy/acet kit on a soft flame.

I just use a 1" copper end cap as a melting pot. Not a lot of capacity but works for what I need it for.

Thanks for the suggestions.

If you use that pipe deal, you should try to put a lip on it. Otherwise, I would think you spill hot solder everywhere?

Aces'n'8s said:

If you use that pipe deal, you should try to put a lip on it. Otherwise, I would think you spill hot solder everywhere?

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Actually, I was only going to fill it about 2/3 full for that very reason. But that is a good point to bring up.

xjbrett said:

I just use a 1" copper end cap as a melting pot. Not a lot of capacity but works for what I need it for.

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X2 on the copper end cap, Very good heat transfer, I just drilled a small hole and threaded a 2" 10-32 along the top edge for a handle to clamp in the vice to hold while tinning some 4 GA wire.

I've replaced plenty of connectors, ground clamps, and stingers, never bothered to solder any of them, never a problem. Cant see it doing anything but helping, but if those clamps and whatnot were designed to be soldered they wouldnt have the set screws in them. Come to think of it, I dont think I've even seen a welding cable with a soldered end.

You can buy solder lugs @ hardware store's that you can put into the connectors and then heat up with a torch, then you just insert the wire. That's what I do.

kwrangln said:

I've replaced plenty of connectors, ground clamps, and stingers, never bothered to solder any of them, never a problem. Cant see it doing anything but helping, but if those clamps and whatnot were designed to be soldered they wouldnt have the set screws in them. Come to think of it, I dont think I've even seen a welding cable with a soldered end.

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Before I crimp the lugs, I've always put some Penetrox on them for good measure. I'm not worried about electrolysis between dissimilar metals, but I figure would provide a modicum or corrosion protection. Concerning lessening resistence....I don't know?

I like to solder (tin) the ends, and then I hold it in with the set screw.

Over time it prevents the ends from fraying and the screw eventually digging through the cable.

I just flux the bare end of the cable then (if using a battery end) I put the end in the vise put some flux in the end heat the end with mapgass/propane melt solder into the cable end 1/2 way full then push the cable into the cable end let cool

for just soldering the bare end of the cable so it doesnt fray I would do the 1" cap thing but dip and pull out after the solder has worked into/around the cable

the Biggest problem I see with people and soldering is flux

most people thing Rosin core solder has the flux inside (which it may) but it always works better when you use paste flux

Read this, there's some good info in it that's relavent.
http://www.pirate4x4.com/forum/showthread.php?t=389055&highlight=dlo

MarkW said:

I like to solder (tin) the ends, and then I hold it in with the set screw.

Over time it prevents the ends from fraying and the screw eventually digging through the cable.

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I usually fill the terminal with solder, then throw it on the ground to coat the inside with solder, first. Don't know why, that's what dad taught me.

But yeah, I could see tinning the ends even if you're using a set screw, but I'd expect it to break apart pretty easily if it wasn't a lot of solder.

olyfj40 said:

You can buy solder lugs @ hardware store's that you can put into the connectors and then heat up with a torch, then you just insert the wire. That's what I do.

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No one seemed to pay attention to this post but he's right. Its the quickest and best way to do this. Del City has them. Link

guidolyons said:

X2 on the copper end cap, Very good heat transfer, I just drilled a small hole and threaded a 2" 10-32 along the top edge for a handle to clamp in the vice to hold while tinning some 4 GA wire.

Click to expand...

Vortec_Cruiser said:

I have several welding cables, which I need to attach ends to. In the past, I have used a propane torch with a roll of solder, but that is a slow process. I thought about making a small melting pot, which I could heat with my acetylene torch. I could melt some lead in it, and add some flux just as I put the exposed end of the cable in.

Here's pics of the cable end and the small pot I was going to make. It's just some 3/4" ID steel tube, and I would weld a small plate to the bottom of it. Does anyone have a better idea for soldering several ends?

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You should never sloder or tin welding cable connections! Is causes up to 5times the resistance of copper, and causes excessive heat.... this could also damage your equipment! They make copper sleeves to keep wire from fraying, otherwise just insert the bare wire and tighten the set screw.

Wires soldered in this manner often break right at the solder. Soldered part is rigid and nonsoldered part bends. Where's it going to bend? Right there the strands will fatigue and fail. This is a BAD IDEA.

metalmagpie