To solder new power cables or not ?

[jaso1]

So I've got some new cable of approx 8mm copper core od. an have got some zink coated copper terminal ends to use .

This is the bit I'm not sure which way to go , to solder ends on cable or just crimp ?

I know that vibration is an issue for soldered on ends but probably has better conductivity between ends and the cable , as long as vibration doesn't break the solder joint .

Crimp only and no need to worry about a break in the joint , but might not carry current as well ?

Is this even a problem or am a idiot who thinks about this crap too much ? 

I spose regardless the new cables will carry more current easier as it is larger and also new cable , I have a feeling my earth cable has some green crud growing up the middle or the copper core at present .

[Howie]

Properly crimped (some old time auto parts stores have the equipment) should not be a problem.  Shrink wrap is a good idea too.  I don't think soldering and vibration will be a problem with a cable that large.

[Speeddog]

I solder 'em.

[jaso1]

Thanks guys .

I might go the solder route then .

cheers

Jason.

[suzyj]

I soldered mine, mainly because I couldn't find a crimp tool large enough.

[ducpainter]

I solder 'em.

me too

[Langanobob]

I also solder them, mainly because soldering is fun (yeah, I know, I hear it all the time "Get a life")  and I put shrink wrap over the joint area to support it from vibration damage.   

[ducatiz]

crimp with generous silver paste
shrink to cover
it will work perfectly

the main problem with crimping big wires is contact area.

with soldering, if you don't do it right, it can increase Ωs whereas a bad crimp with silver paste will work just fine.

then again, i do both depending on the application, but for something on the battery, i'd crimp & paste it.

[battlecry]

I crimp and solder.  FAA says good crimps better for high vibration environment.   NASA solders.  With heavy cables I prefer to seal the terminal cable strands from further corrosion using solder.   I grew up in a fierce corrosion environment.

[bikepilot]

I also solder and crimp.  Crimp-only tends to be more likely to corrode and build up resistance over time.  Either will work, its just a matter of for how long.  If the bike isn't exposed to corrosive environments much it might be a decades before you get much corrosion, but I ride year round no matter what the weather so corrosion resistance is needed.

[2-Skinny]

I use dialectric grease on all terminal/exposed areas to prevent corrosion and DeOxit to remove corrosion...

[ozs4]

Crimping is the preferred method in the aerospace world.  That is good enough for me.  If you casnt find a crimper big enough, just take the cable to an auto electrician and ask them to crimp them.

[suzyj]

Crimping is the preferred method in the aerospace world.  That is good enough for me.  If you casnt find a crimper big enough, just take the cable to an auto electrician and ask them to crimp them.

In the electronics research world where I work, we don't generalise like that.  Some connections get soldered, some crimped.  If we're making many hundreds or thousands of the same type of connection, then we invariably choose crimp because we can set up a crimp tool to ensure repeatability.  For half a dozen connections, solder is generally preferred because we aren't in a position to do test crimps and destructively test them.

The key with either termination method is that it has to be done well.  A crimp made without the correct tool will generally fail in pretty short order.  Similarly, a soldered connection made by someone who isn't proficient at soldering, and without good quality tooling, will also fail.