making 2/00 cables need lugs

westbranchwestbranch Solar Expert Posts: 5,123 ✭✭✭✭
I am making some cables using 2/00 welding cable to go from the Batt. Manufacturers buss barr to the CC etc.

I got some good copper lugs for this project but found that they have 1/2 inch holes and the buss barr has 3/8" diam. holes & bolts, so now I am looking for lugs with 3/8" holes.
Tried all the local supply places and there is nothing available that gives at least > 1 inch contact between the cable and the lug. Lots with short connections < 1 inch.

Any recommendations for a Net Vendor with a suitable lug?
KID #51B  4s 140W to 24V 900Ah C&D AGM
CL#29032 FW 2126/ 2073/ 2133 175A E-Panel WBjr, 3 x 4s 140W to 24V 900Ah C&D AGM 
Cotek ST1500W 24V Inverter,OmniCharge 3024,
2 x Cisco WRT54GL i/c DD-WRT Rtr & Bridge,
Eu3/2/1000i Gens, 1680W & E-Panel/WBjr to come, CL #647 asleep
West Chilcotin, BC, Canada


  • mike95490mike95490 Solar Expert Posts: 8,067 ✭✭✭✭✭
    Re: making 2/00 cables need lugs

    Try Mc Master Carr supply . They have a lot of lugs. I ended up making mine out of tinned copper pipe.
    But be warned - the welding cable has very fine strands, and needs a good lug, and good compression to fuse the wires together and to the lug. Often, the fine strands work themselves loose........
    Powerfab top of pole PV mount | Listeroid 6/1 w/st5 gen head | XW6048 inverter/chgr | Iota 48V/15A charger | Morningstar 60A MPPT | 48V, 800A NiFe Battery (in series)| 15, Evergreen 205w "12V" PV array on pole | Midnight ePanel | Grundfos 10 SO5-9 with 3 wire Franklin Electric motor (1/2hp 240V 1ph ) on a timer for 3 hr noontime run - Runs off PV ||
    || Midnight Classic 200 | 10, Evergreen 200w in a 160VOC array ||
    || VEC1093 12V Charger | Maha C401 aa/aaa Charger | SureSine | Sunsaver MPPT 15A

    gen: ,

  • tons001tons001 Solar Expert Posts: 71 ✭✭
  • Blackcherry04Blackcherry04 Solar Expert Posts: 2,490 ✭✭✭
    Re: making 2/00 cables need lugs

    This where I get mine, Free Shipping, figure that into your cost per lug. If your buying in bulk you can save more. They also make cables for $1.00 per lug with heat shrink. They do a nice job.
  • gww1gww1 Solar Expert Posts: 963 ✭✭
    Re: making 2/00 cables need lugs

    I just bought 3/8ths luggs from naws, about 38 of them for 4/0 wire. I needed 5/16.
  • RybrenRybren Solar Expert Posts: 348
    Re: making 2/00 cables need lugs

    waytekwire has a [URL=" lugs&psType=P&sc=1427"]large selection of lugs [/URL] and great prices on MRBF fuses (for the Blue Sea type battery post fuse holders)
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