[RE-wrenches] Large ferrules

[Chris Sparadeo]

It was my understanding that these compression lugs for DC connections are
typically rated for fine stranded conductors. But I’m partial to ring
terminals, so the pin adapter does sound like a good option as well.

On Wed, Aug 27, 2025 at 3:00 PM Maverick Brown via RE-wrenches <
re-wrenches at lists.re-wrenches.org> wrote:

> For the six AWG and smaller I have a nice crimper that does a great job
> making hex shaped crimps.
>
> For the 2/0 and 4/0 cables, I just slide the ferrule onto the conductors,
> then insert the ferrule + conductors into the lug. And then tighten the set
> screw to the specified torque. As a test, I have removed the cable to see
> how the ferrule survived the set screw. The ferrule was not ripped and kept
> the wires inside. The wires fit the backside of the lug and were
> semicircular as proper and the set screw made a perfect spot for it to land
> onto the ferrule. I usually double check the torque at the end of doing the
> other wires to make sure the battery cables are secure.
>
> This method may not be scientific. I do have a battery cable crimper for
> regular lugs, but it make a diamond shaped crimp that doesn’t seem as nice
> as just using the set screw in the terminal.
>
> Thank you,
>
> Maverick
>
> Maverick Brown
> Off-Grid Solar Commander since 2006
> Maverick Solar Enterprises, Inc.
>  • Solar Commander Remote Power
>  • SunFlow Systems Cathodic Protection
> maverick at mavericksolar.com
> 512-460-9825
>
>
>
> On Aug 27, 2025, at 9:41 AM, William Miller via RE-wrenches <
> re-wrenches at lists.re-wrenches.org> wrote:
>
> 
>
> Friends:
>
> More inverters these days present lugs for battery connections instead of
> studs. I bought some 2/0 and 4/0 ferrules to accommodate the fine stranded
> MTW we use. I have a cheap hex crimper but the results are poor with a
> sharp “wing” on either side of the crimp.
>
> What does the hive mind suggest for a ferrule and crimper for these larger
> wire sizes?
>
> Thanks in advance.
>
> William Miller
> Miller Solar.com
> 805-438-5600
> www.millersolar.com
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