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GlennAB1
User
Aug 28, 2009, 9:20 AM
Post #3 of 12
(253 views)
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The first thing you have to do is make sure there is plenty of excess length in the cables so they can be cut and still have plenty of cable left. If not, you'll have to replace the whole cable.
To replace the end, cut the old terminal off flush and then strip back about 1" of insulation and wire brush the wire thoroughly. Make sure there is no corrosion at all on the wire or replace the cable. The easiest way is to install the battery first and then put the new cable ends on the battery. It will be easier to insert the cable into the cable end that way. "wire brush the wire thoroughly" In doing so, you may introduce a dissimilar metal to the cable that in a very short time causes the cable to be blown out with corrosion. Sig removed
(This post was edited by Hammer Time on Sep 8, 2009, 4:14 AM)
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GlennAB1
User
Aug 28, 2009, 10:03 AM
Post #5 of 12
(241 views)
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There should be no need to wire brush the stripped cable unless it already has signs of corrosion. If that is the case it will begin to corrode pretty rapidly, especially with the insulation removed, it's now exposed to a more corrosive environment. After stripping the insulation, if the cable isn't corroded, the only thing I'd do is spray an electro contact cleaner on it. I consider replacing battery terminal ends to be a somewhat temporary fix, the cable always corrodes fairly rapidly at the terminal connection. Sig removed
(This post was edited by Hammer Time on Sep 8, 2009, 4:14 AM)
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Hammer Time
Veteran
/ Moderator
Aug 28, 2009, 10:09 AM
Post #6 of 12
(237 views)
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There should be no need to wire brush the stripped cable unless it already has signs of corrosion. If that is the case it will begin to corrode pretty rapidly, especially with the insulation removed, it's now exposed to a more corrosive environment. After stripping the insulation, if the cable isn't corroded, the only thing I'd do is spray an electro contact cleaner on it. I consider replacing battery terminal ends to be a somewhat temporary fix, the cable always corrodes fairly rapidly at the terminal connection. Not if it's done properly and sealed with grease or battery terminal sealer when finished. I agree a whole new cable would be much better but when it's a couple hundred dollars vs $10, this may have to be sufficient. 78 Corvette Pace Car For Sale-18k mi orig-Florida 
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GlennAB1
User
Aug 30, 2009, 8:03 PM
Post #12 of 12
(183 views)
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The first thing you have to do is make sure there is plenty of excess length in the cables so they can be cut and still have plenty of cable left. If not, you'll have to replace the whole cable.
To replace the end, cut the old terminal off flush and then strip back about 1" of insulation and wire brush the wire thoroughly. Make sure there is no corrosion at all on the wire or replace the cable. The easiest way is to install the battery first and then put the new cable ends on the battery. It will be easier to insert the cable into the cable end that way. "wire brush the wire thoroughly" In doing so, you may introduce a dissimilar metal to the cable that in a very short time causes the cable to be blown out with corrosion. By this logic the battery cable ends that are installed by the factory should cause a whole host of corrosion problems.
All metals do not react the same. Copper with lead has much less corrosive tendencies than Copper with steel.
To be honest, I had to do some review because in my work I deal mostly with steel and aluminum and we simply try to avoid any/all dissimilar metals contact in order to reduce corrosion. Truth is, copper is one of the least reactive metals and cathodic in nature. Copper (being cathodic) combined with steel (being anodic) from a wire brush, if anything, any trace element of steel left on the copper will corrode...... yep, the steel would corrode, not the copper. Come to think of it, that's why I've had to wire brush the rusted spot where the battery cable grounds and not had to do anything (other than clean) the cables terminal end. Also, the corrosion is most likely when the metals are in an electrolitic environment. Copper cable with lead in a nearly air tight/liquid tight contact won't readily corrode, but over time the lead will because it is anodic in nature with copper. This is also why the steel hardware corrodes and not the led terminals. I apologize to Hammer.
Sig removed
(This post was edited by Hammer Time on Sep 8, 2009, 4:14 AM)
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