How do I join heavy duty (60 amp) electric flex?

firstascent2002

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12 Jan 2004
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All I can find are poxy little crips from B and Q or 40 40 amp plastic blocks at fource four. How have others done this. I hope this windlass ends up being worth all the trouble!
J
 
Find an electrical wholesaler - buy a 100 amp double pole Henley Block - change from a tenner - this provides up to 25 sq. mm. terminals.

It's like a really big connecting strip / chocolate block.

Fully insulated but not waterproof.
Only needs a large screwdriver.
 
Go to an electrical wholesaler, and ask for heavy duty inline crimps. They are made for all sizes of cables. Over the inline crimp, "bandage" it with self amalgamating tape, for mechanical insulation, and then shrink adhesive lined heat shrink sleeving over the lot. You will need to borrow a heavy duty crimp tool. If you are down my way, you could borrow mine.

This is what I had to do when in the MN to repair deck container cables and crane cables that had been damaged. This was easier and cheaper than replacing the whole cable.

This type of repair was also carried out when repairing a severely damaged section of cables after a fire onboard - while transiting the Suez Canal!! It lasted for another 10 years until the ship was scrapped.
 
You could always get a set of the plug and sockets used for charging electric forklifts, there is a name for them, cant remember it, but if you go to any forklift service centre they will keep you right.
There is also the option of using welding cable extension plugs and sockets which would be a cheaper option and easier to come by, from BOC or any welding gear suppliers.
This gives you the option of unplugging them if you need to isolate them for any reason without having to cut the cables.
 
See http://www.sicame.co.uk/Section1/1.01-1.02.pdf

They have a wide range used in the power industry. Very easy to use 'cos they are a mechanical bolted assembly and once shrink wrapped they will operate under water.

They also do some nice brass blind terminal lugs with self shearing bolts from their 11 and 22KV ranges. I use these on my boat and they are super reliable in wet marine applications.


I've spent about £8M or so with them over the years and can recommend their products.

You may have to go to a distributor.
 
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