[Al Skierkiewicz]

Zack,
Please look closely at the bitmap in the above post. Teams frequently do not strip enough insulation from the wire before insertion in this lug. At least 1/8 inch of wire should extend beyond the wire clamp before you tighten the screw. These types of lugs are not tolerant of a lot of movement in the wire. Many teams do not realize that you can route the wiring either straight up from the terminal or out to the side of the battery depending on how you mount the battery in the robot. Pick the orientation that is right for you. Once terminated bring the red and black wires close together and tywrap them in parallel. This will reduce the amount of flexing that takes place at the lug. Solder helps this type of connection. It does take a larger tip and at least a 35 watt iron. Remember to add a good amount of solder to the tip of the iron to help conduct the heat and then add solder to the end of the wire where it protrudes from the lug. Be sure that the wire and the lug are both melting the solder for the best connection. (Never tin the wire before you insert it in the lug.) Only add enough solder to the wire so that you just start to see it wicking under the insulation. If you use a torch, remember to remove the flame when testing the melting of the solder. Solder should flow freely after the torch is removed. If at an event, please remember there is no open flames allowed.