Make Your Own Battery Cables Part 2 - Adding the Lugs | Polar Wire

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In this video, we'll add a lug to our stripped wire

and I'll show you a niftly electrician's trick for getting uncooperative stranding into a lug

Hi, I'm Russell with Polar Wire Products

home of Arctic Ultraflex Blue ultraflexible Arctic grade wire

In a previous video I showed you how to strip large gauge fine stranded wire with a rotary cable stripper

We gave the wire a clean, flat cut and stripped the end,

and the stranding is in great shape— undamaged and compact

The insulation is stripped back just enough that the conductor will fill the lug completely

and make a good solid mass without any voids

And this cable is ready for the lug

Strand turnback reduces the electrical flow,

so for the best conductivity, check to make sure all the strands make it into the lug

Terminals that have a slight flare or funnel entry at the bottom of the barrel

make it easier to insert the wire

The funnel entry steers all the stranding right into the barrel

So what if your wire has gotten a bit frayed or feathered out and you can't get it into the lug?

Here is a great little trick electricians use

Smooth the wire roughly back into shape

Take electrical tape, and starting a half an inch or so down the jacket

wrap a light layer up and around the copper, pulling it tight to compress the stranding

Then work your way back down the jacket

Insert the taped end into the lug, and holding the lug in place with the wire fully inserted,

peel the tape out from under the barrel, pulling it gently sideways

to ensure the strands stay inside the barrel

Notice we don't have any strand turnback

We got all the strands into the terminal, and now I can give this a good solid crimp

Our cable makers use this trick when they are working with really large gauge

like this 500 MCM wire

It reallly helps to keep the stranding under control

One more thing before you crimp

Be sure to turn the lug on the wire to the placement you want

When we make our custom cables we like to center the wire's legend

on the side of the lug that will be most visible, so that the wire information can easily be read

Be sure to determine how the ends should align with each other when your cable is in use

Here is what a good crimp will look like on the inside

The copper stranding has been compressed into a solid mass and there aren't any air pockets

that can cause corrosion, hot spots, or other problems later

Did you know Polar Wire makes custom cables?

We use our Arctic Ultraflex Blue ultraflexible arctic grade wire

and high quality parts and processes to build flexible, durable cables

that outlast and outperform the others

Visit our website at and checkout our huge online store

Thanks for watching!