Sourcing electrical connector, thick cable to thin?

[skyflyer]

I have just fitted a new shore-powered battery charger where the now defunct old one used to be, which is located some distance from the battery and thus has some very thick cables with ring connectors on the ends that are too large to fit the new charger! I'm not sure its possible to fit a smaller connector on the cable ends so I propose to run a thinner cable for a few inches from the charger terminal to a junction box where I can connect the thick and thinner cables together. the voltage drop along four or five inches of thinner cable will be negligible.

However I cannot find (= don't know the terminology or where to source) a suitable junction box which will accept a cable that is about 6mm diameter or has a screw post with nut to accept the ring connector

Any ideas?

 

[sailorman]

http://cpc.farnell.com/webapp/wcs/s...e ring terminals&pageSize=25&showResults=true

 

[skyflyer]

thanks sailor man, but I haven't explained myself well. Its not the ring terminal itself that I need, they are on the cable ends already its some sort of damp-resistant box to connect the two ring terminals of vastly different sizes!

 

[theoldsalt]

You may be searching for a "junction box". Try searching for a "bus bar". That may be more suitable.

eg http://www.thetoolboxshop.com/0-005...se-2456.html?gclid=CPvs7KqljMQCFTDHtAodGjUA6g

 

[pvb]

A "bus bar" has lots of terminals all connected, which isn't what you need. Search instead for "commoning post", eg http://www.acornengineer.co.uk/show_cat.php?id=121&start=20 or http://www.altecautomotive.co.uk/po...m6x29-8mm-x28m8x29--10mm-x28m10x29-3295-p.asp

Or you could simply put a ring connector on the end of the charger cable and use a nut & bolt, with washers, to clamp the 2 ring connectors together. Insulate with tape or heatshrink.

 

[theoldsalt]

The reason I suggested using bus bars is to avoid multiple cables being attached to a single battery post - which is bad practice. I always suggest taking multiple cables to a bus bar and connecting the bus bar to the battery post using a single heavy duty cable.

 

[pvb]

The reason I suggested using bus bars is to avoid multiple cables being attached to a single battery post - which is bad practice. I always suggest taking multiple cables to a bus bar and connecting the bus bar to the battery post using a single heavy duty cable.

The OP simply wants to connect a thick wire to a thin wire.

 

[theoldsalt]

The suggestion was for the OP. I'm sure he can answer for himself or ignore it if he wants to !

 

[lw395]

A "bus bar" has lots of terminals all connected, which isn't what you need. Search instead for "commoning post", eg http://www.acornengineer.co.uk/show_cat.php?id=121&start=20 or http://www.altecautomotive.co.uk/po...m6x29-8mm-x28m8x29--10mm-x28m10x29-3295-p.asp

Or you could simply put a ring connector on the end of the charger cable and use a nut & bolt, with washers, to clamp the 2 ring connectors together. Insulate with tape or heatshrink.

I have used a scrap of GRP sheet, put the bolts through that, then they can't touch each other.

 

[pvb]

I have used a scrap of GRP sheet, put the bolts through that, then they can't touch each other.

Yes, that'd work well.

 

[philip_stevens]

I have just fitted a new shore-powered battery charger where the now defunct old one used to be, which is located some distance from the battery and thus has some very thick cables with ring connectors on the ends that are too large to fit the new charger! I'm not sure its possible to fit a smaller connector on the cable ends so I propose to run a thinner cable for a few inches from the charger terminal to a junction box where I can connect the thick and thinner cables together. the voltage drop along four or five inches of thinner cable will be negligible.

However I cannot find (= don't know the terminology or where to source) a suitable junction box which will accept a cable that is about 6mm diameter or has a screw post with nut to accept the ring connector

Any ideas?

I think that what you might need are these - http://uk.rs-online.com/web/p/terminal-block-accessories/6558858/ or these - http://uk.rs-online.com/web/p/non-fused-din-rail-terminals/4587781/- though I cannot find the individual posts on the RS site - you may need the help system to find the size you want. You will need a short piece of asymmetric DIN rail inside an IP65 or higher box (Wiska maybe) with waterproof glands.

 

[VicMallows]

All suggestions sound rather overkill to me. Presumably the existing 'thick' cable is stranded. I would reduce the existing cable by removing enough strands to fit the largest ring-crimp which will comfortably fit the new charger. (ideally gradually over several inches to reduce fatigue). Then suitably insulate.

 

[prv]

All suggestions sound rather overkill to me. Presumably the existing 'thick' cable is stranded. I would reduce the existing cable by removing enough strands to fit the largest ring-crimp which will comfortably fit the new charger. (ideally gradually over several inches to reduce fatigue). Then suitably insulate.

I did something quite similar when I added a high-current foredeck socket for the dinghy pump. Because of the length of the run, the cables needed to be much larger than the socket would normally accept. I tapered them down over a couple of inches and then covered with adhesive-lined heatshrink. Looked quite neat.

Pete

 

[lpdsn]

The simplest solution is to use a terminal post (at the bottom of this page) http://www.seascrew.com/browse.cfm?BUS-BARS--CONNECTORS--TERMINAL-BLOCKS&l=0000000211 (Seascrew call them base junctions which may well be the correct name).

Size it to fit the internal diameter of the existing ring terminal(s). Make up a new cable with a ring terminal to match and put them on the same post.

 

[skyflyer]

All suggestions sound rather overkill to me. Presumably the existing 'thick' cable is stranded. I would reduce the existing cable by removing enough strands to fit the largest ring-crimp which will comfortably fit the new charger. (ideally gradually over several inches to reduce fatigue). Then suitably insulate.

Great idea, why didn't I think of that. The effect is the same, of course!

 

[peteK]

Use a choc block connector remove the screws and take out the metal bit,overlap the thick and thin wire and tighten both screws on to wires,finish off with heat shrink..

 

[Poignard]

If you have a look at the '12voltplanet' website you might find something suitable :

http://www.12voltplanet.co.uk/

 

[niccapotamus]

If you have a look at the '12voltplanet' website you might find something suitable :

http://www.12voltplanet.co.uk/

they will have waterproof junction boxes as does ebay http://www.ebay.co.uk/itm/121410206868?_trksid=p2059210.m2749.l2649&ssPageName=STRK:MEBIDX:IT - that is if I'm reading your question right. You might have to be a bit creative within the box but the waterproofness, together with some vaseline/acf50 to stop damp might mean that the good old strip connectors would do the job?

 

[Spyro]

I'd wrap solder and heat shrink.

 

[Len Ingalls]

Check with a electrician supply. for weatherproof pvc box & cover.
http://www-public.tnb.com/ps/endeca...=3819+601+1006&Ne=&Ntt=&Ntk=&Ns=&grid=&parts=

Make your joins inside weatherproof box,using terminal strip,bus bar or "base mounts".