Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable

[thinwater]

Originally Posted by ayates

Wire OD (#2) is 5/16" and the power lug ID (#1-2) is 3/8"


Thanks,

Allan.

That is right on the wire spec (remember to subtract the insulation) (5.072 16ths).

[wingless]

Originally Posted by wingless

As you've stated, the ID for the cable is too large.

Either the lug is defective, with the ID too large, or the wire is defective, with the OD too small. Can the lug bore ID and the wire OD be measured?

Originally Posted by ayates

Wire OD (#2) is 5/16" and the power lug ID (#1-2) is 3/8"

According to this table, the stranded wire diameter is too small.

[sailah]

I had excellent results crimping 2AWG using high quality Molex lugs I bought from Waytek wire and FTZ crimpers. They were not the "power lugs" but rather normal flared starter lugs. Somehow Waytek site is down but Mouser also has them and price is pretty good.

https://www.mouser.com/ProductDetail...HNUbu96rBik%3D

Looking at FTZ site they list a genuine 2AWG lug and a 1-2 lug. I'd try a lug for 2AWG first since I also used Ancor 2 AWG cable and same crimpers you have.

FTZ Industries

[john61ct]

Originally Posted by wingless

According to this table, the stranded wire diameter is too small.

That's not specific to Ancor, never heard of that maker.

To me, once the OP has determined their wire id in fact genuine Ancor, such comparisons are just a distraction from the OP's objective.

[john61ct]

Originally Posted by sailah

Looking at FTZ site they list a genuine 2AWG lug and a 1-2 lug. I'd try a lug for 2AWG first since I also used Ancor 2 AWG cable and same crimpers you have.

FTZ Industries

Distinction in the part #s - besides bare copper vs tinned - seems to be "light duty" vs HD rated for 600V

I still think a proper crimp can likely be made with the existing fittings, if everything is genuine

Contacted Alan Ferber yet? alan@baymarinesupply.com
+1 619 320-5899

[S/V Alchemy]

I have just been crimping up 2 ga. tinned wire with tinned power lugs using the FTZ crimper without any problems. I have to be careful to get all those strands in properly. The crimps are good. https://scontent.fybz2-1.fna.fbcdn.n...ff&oe=5D8156EA

[john61ct]

If you linked to the specific lugs you use or gave the part# that would help, as well as the setting on your crimper


e.g.

91747, the 1-2 AWG "heavy duty" version using the Pink⁄H-H setting for a 3⁄8" stud

while 91037 is a "starter lug" specifically for #2 only, so has a tighter fit and uses Brown/J-H

And with all the variability out there over time, switching from Taiwan to mainland factories, knockoffs etc

to make sure we're all on the same page, this #94284 should be the one "FTZ crimper" we're all referencing right?

https://shop.marinehowto.com/product...lug-crimp-tool

[KP44]

The lug looks like a size 1, which is far too large for #2 wire.

Maybe the packaging says #1 - 2 lugs. Meaning 2 pieces of size 1 lugs.

Just get some #2 lugs and they will work.

[john61ct]

Originally Posted by KP44

The lug looks like a size 1, which is far too large for #2 wire.



Maybe the packaging says #1 - 2 lugs. Meaning 2 pieces of size 1 lugs.

No as stated several times, these particular FTZ lugs are for both #1 and #2 AWG wire, which of course is the meaning of the

1 - 2

marking right on the lug.

Open the FTZ catalog, or that of your favorite reseller e.g. fisheries supply and text-search for 91747 to see it.

Of course buying a different lug is one solution, but IMO if the wire lug and crimper are all genuine it's just a question of tool setting and a little technique as outlined in the posts I linked to above.

[GordMay]

FTZ 91747 ➥ https://www.iewc.com/products/wire-m...5-9fc3324e9562

[Dsanduril]

FTZ makes two sets of "pink H-H" lugs - the 9173x are rated for 2AWG, the 9174x are 1-2. I'd try to get at least one of the 9173x series and test it out.

[waterman46]

Originally Posted by GordMay

FTZ 91747 ➥ https://www.iewc.com/products/wire-m...5-9fc3324e9562

Gord, isn't that picture of a lug for the big double ought wire, not a #2, or is that what you intended to show?

[GordMay]

Originally Posted by waterman46

Gord, isn't that picture of a lug for the big double ought wire, not a #2, or is that what you intended to show?

I thought I was showing a discrepancy betwixt the pictured lug, and the written description. It turns out that the 2/0 Lug picture is used for all the cable lugs.
However:
The FTZ 91747 has an inner barrel diameter of 0.395"
#1 & #2 AWG cable diameters are 0.289" & 0.2576" respectively.
#2/0 AWG cable diameter is 0.365".
Something is wrong here. Maybe it's me?

[GordMay]

FTZ Lug Specs

[CharlieJ]

Is the insulation marked as "Boat Cable", UL 1426? If not, it could be SAE cable which, on average, has about 12% less copper in it and, as a result, has smaller OD.