XS Power provided an assortment of 0-sized ring terminals for us to use.

You can see that these are not solid ring terminals. That’s important to note when crimping, as you’ll soon find out.


This is a proper, monstrous hexagonal terminal crimper. It is a beast.

Unfortunately, it’s designed to work with solid terminals and slightly different cable.


Nothing a little BFH can’t fix.

We simply mangled the terminals into a better connection so that they could not be pulled off. I wouldn’t want to hang myself from a building with the terminal this way, but it will be more than good enough for our needs.


Glue line is applied to reduce the exposed conductive area and to help keep the outer insulator in place.


Here’s the finished short cable that will go between the battery positive and the contactor.
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Posted in: Project SC300
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Tuesday, March 27, 2018 9:37 AM
I am watching carefully. Lot of thorough work. It seems there are big plans for the car.
Tuesday, March 27, 2018 12:16 PM
I remember working with 1/0 gauge wire doing a stereo install, and having to use a large screwdriver, hammer and plyers to get those ends crimped. Worked fine!
Tuesday, March 27, 2018 2:07 PM
I've always had good luck mounting GPS antennas to the rear package shelf under the rear glass.
Saturday, March 31, 2018 2:07 PM
@brianJ never thought about mounting it inside the car! That could probably work, too!
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