[Richard Wallace]

Originally Posted by Al Skierkiewicz

I have found that crimping the connectors that Art shows in the corner of a vice works OK. Place the connector in the vice at a 45 degree angle with only half the connector in the jaws. Crimp half the connector at the corner then turn over and crimp the othe half. The result will leave an "X" shape on the connector. Follow with a good solder job and insulate with heatshrink. These connectors are available in small quantities at Home Depot and other home stores.

When used correctly (for example, following the method Al describes above) crimp type terminals work well. When used correctly, the lugs provided in the 2006 FRC kit also work well.

Please remember also to secure and insulate the finished connection between the 6 AWG cable terminal and the battery terminal. Locking nuts or lock washers should be used to ensure that the screw will not work loose, and shrink tubing or a good multi-layer tape job should be used to ensure that the battery terminals won't accidentally get short-circuited.

On a closely related subject -- I consider temporary removal of the battery terminal insulation, for the purpose of attaching battery charger alligator clips, to be an unsafe practice. Fitting your battery charger with Anderson connectors (1) prevents incorrect polarity connection to the battery and (2) prevents accidental battery terminal shorting.

I know this thread is about an off-season project. I also know that safety is a habit, not an option that can be turned on or off at will. The available fault current from an 18Ah lead acid battery is a hazard that we should respect.