Re: Battery connections
 

Thanks everyone for all the suggestions. My team has decided to use a compression lug (bluedie374) COVERED WITH heatshrink tubing. The full pole connection will have to be isolated. Then we'll validate the electrical resistance (should not exceed milliohms), and then we'll do a pull strength test. The tool used for compression is taken from HomeDepot.

Re: Battery connections
 

I've used this crimper with good results. The dies are not perfect and their sizes are weird and it flattens the hex a little and puts "wings" on the sides of the crimp, but it goes make a good solid connection.

Re: Battery connections
 

Crimp, solder with a blowtorch, repeat.

Re: Battery connections
 

A proper crimp does not need solder; indeed, the 'right' crimp is made worse with solder.

That being said, a 'pretyty close' crimp can be improved with solder.

We have used the crimping die on these pliers with great success. Two students squeeze it shut, it does take some effort.

Re: Battery connections
 

I use a very small screwdriver or awl from the "contact" side of the connector to push/pull the spring out of the way, then pull the wire and pin out the other side. It's easy. I even used a paper clip once.