[TCML] Source for copper hardware

[Dave Leddon]

Hi Paul,
Thanks for the crimper endorsement.  I notice a bunch of these for 
sale on Ebay at lower prices so that's also an option

Dave

At 08:19 AM 4/1/2010, you wrote:
>I'm a Harbor Freight tools nut and own way too many of their tools, 
>including this hydraulic crimper. I caught it on sale a couple of 
>weeks ago and couldn't resist. If you buy it, I do not think you 
>will be at all disappointed. It isn't on sale now and I do think the 
>price is a bit high when not on sale. If you aren't in too big of a 
>hurry, though, they usually put the same things on sale periodically 
>and if you keep you eyes out, you will most likely see it go on sale again.
>Paul
>Think Positive
>
>----- Original Message ----- From: "Dave Leddon" <dave at leddon.net>
>To: "Tesla Coil Mailing List" <tesla at pupman.com>
>Sent: Tuesday, March 30, 2010 11:48 PM
>Subject: Re: [TCML] Source for copper hardware
>
>
>>Jim,
>>You've got a couple of really good suggestions here.  I have 
>>everything needed to do silver brazing, except the bottles, which I 
>>can retrieve the next time I'm in Las Vegas.  So this would be a no 
>>cost solution. However, there is one undesirable aspect of 
>>soldering lugs that might also apply to brazing.  Solder can wick 
>>up the wire and inch or two resulting in an inflexible cable near 
>>the termination.  A small thing but it always bugged me.  And then 
>>there's the damage to the insulation which could be great at 
>>brazing temperatures.  Your other suggestion that I get the 
>>connections crimped at my local welding store has great merit since 
>>I usually buy my lugs there anyway.  But maybe the best solution, 
>>since I seem to be fabricating a lot of heavy-duty cables lately, 
>>would be to buy one of these:
>>http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=66150
>>
>>Dave
>>At 06:16 PM 3/30/2010, you wrote:
>>>Dave Leddon wrote:
>>>>I've been trying to eliminate hot spots in the primary circuit of 
>>>>a relatively high current (~3000 amp) drsstc by replacing high 
>>>>resistance connection points with copper.  Even a one-inch length 
>>>>of 3/8-inch brass bolt can generate enough heat to melt the 
>>>>solder right out of a terminal lug.  Which raise another 
>>>>interesting point, what about solder?  It has ten times the 
>>>>resistance of copper so maybe all lugs should be crimped.
>>>>I only soldered them because I don't own a crimper large enough 
>>>>to deal with #2 welding cable.  But I digress.  I've not had any 
>>>>success locating a source for copper nuts and bolts, probably 
>>>>because copper isn't strong enough to be consider a fastener, and 
>>>>so have been force to machine my own.  I would much rather just 
>>>>plunk down the credit card.
>>>>Does anybody know of a good source for copper hardware?
>>>
>>>Crimping is common for applications like welding cables.  Most 
>>>welding supply places can crimp connectors on your cable for you.
>>>
>>>"hard solder" (aka silver solder) or brazing is another 
>>>alternative. Much higher melting point.. Hey, an excuse to use a 
>>>MAPP/Oxy or Acetylene/Oxy rig!  I've used one of those inexpensive 
>>>MAPP/Oxy sets with the disposable bottles to do stuff.. It gets 
>>>expensive if you use much gas, but for a small project, it's not 
>>>too bad.  MAPP/SolidOx is another possibility which is a bit less 
>>>expensive for supplies.
>>>
>>>But if you're going to do more than a simple job, it's worth 
>>>getting (or renting?) a real oxy/acetylene rig, like refrigeration 
>>>guys use, with the small bottles.  About $300 or so, including the 
>>>bottles and torch. And brazing/gas welding is actually pretty easy 
>>>(compared to, say, straight stick welding) with a very small 
>>>amount of practice. (as long as you stay away from aluminum.. it's 
>>>just hard, because it melts before it changes color)
>>>
>>>
>>>
>>>Have you looked at "split bolts" used in electrical wiring? They 
>>>also use copper hardware for high current applications, so a 
>>>commercial electrical supplier might have them.
>>>
>>>
>>>Copper hardware is also used in the marine industries.
>>>
>>>And, of course, McMaster Carr might have them..
>>>
>>>But.. what you really want is exothermic welding, aka Thermite. 
>>>Cad-Weld is one trade name.
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>>
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