Slip the cable thru the 500 Amp clamp
Slip on the heat shrink tubing
Measure using the copper clamp contact
Cut at the proper point & remove the insulation
Clamp, Solder & add the heat shrink tubing
Your set of jumper cables
Cut you cabling to length
Tools:
* Vice
* Knife
* Large pilers
* Propane torch
* Heat gun
* Cable cutters or sharp knife
Materials:
* 1 ga welding wire which is
good for 600 amps, very flexible (more than auto grade wire and carries more
amps/volts. 1 ga is more than most folks will ever need yet no where as
expensive as 00-06 ga automotive cable.
* 500 Amp vinyl coated clamps
* Electrical solder and flux
* Lock-Tite
* Heat shrink tubing
The Build:
Layout your cable full length on a
flat surface to get the twist out of it and insure you are getting the exact
length you need.
Since I use welding cable its easy
to cut, but a small pair of cable cutters that will cut up to about 3/4 cable
will work fine and be inexpensive.
Insert one end of the cable into
the handle of the clamp, then add you precut piece of heat shrink tubing.
Using the clamp copper connector and cable measure to see how deep you
need to insert the cable.
Cut off the rubber insulator,
insert into the copper clamp and crimp. Then solder it in place.
Now add you heat shrink tubing and
heat to get a good firm bond.
For Battery cables you will want some heavy duty battery connectors for the positive and negative battery posts
TIP:
The clamps I am using are spring
loaded and use the base of the spring to hold the cable in the handle. I
take a small piece of of heat shrink and place it between the cable and the
spring to keep down wear on the outer cable insulator skin.
Put Lock-Tite on the screw that
holds the copper jaws in the clamp.
Do that for each end and you have a set of really high quality jumper cables that will most likely last a life time.