Technical Cutting Battery Cable

I bought some super flexible battery cable 1/0 from batterycablesusa.com as recommended. Now, I need to cut it to length and then trim back insulation to attach terminals. I have a Dremel with a diamond-coated blade. Any other better ideas?

 

Lots of tools for the job, but what you have should work.
I try not to cut any strands when cutting back insulation, so I'd switch to a razor blade there, but whatever works for you.

 

Hacksaw
I make a few battery cables each year and just use a fine tooth hacksaw. I had some fancy cable choppers and it’s the same amount of filing/deburing either way. Also if you want a fancy look use vulcanizing tape to wrap the gap where the copper is exposed after the end is on.

 

I clamp it lightly in the vise, then use the wiz wheel with plain blade to cut it off

 

I've used cut-off wheels, hack saws when I was young and poor, BUT ! what ever I used I always wrapped the cable tight with masking tape right in the middle of my cut.

Don't know if it really helped but felt like it helped keep the strands tight and together and made a nicer and cleaner cut....


...

 

I cut one yesterday and used a hacksaw. Get some shrink tube that will fit over the copper end and slide it on the cable before you put the end on the cable. Then push it over the cable end with at least 1/2" on the wire and shrink it with a heat gun.

 

x2, then cut with hacksaw or cutoff wheel.

 

Bandsaw. Wear eye protection.

 

These work very well.

 

Bought a pair of these…could not believe how smooth and effortless it was to cut some 1/0 wire…not a tool that I will use a lot, share it with my buddies and it is there if and when I ever need it again.

 

Yeah, those cable cutters are slick. If you go to a place that sells by the foot, they are what's at the ready for doing the job.
The good ones aren't cheap, so you either have to have plenty of uses, friends to share with or willing to spend on a rarely used tool.
There is always debate on solder, but a solid shrink wrap is always agreed. I'd go a step further on that and see about one that has the sealing glue too.
https://www.mcmaster.com/products/heat-shrink-wrap/for-wire-gauge~1-0/

 

@5window, I was in Lewisburg today, if I had known I could have brought my cable cutter pliers with me, they are slick!

 

I bought this cutter/crisper kit a few years back off Amazon, current price is $33.50 and they work fantastic.

https://a.co/d/5Q2QTLu


Old school way would be to use a sharp chisel, but I'd definitely buy the cutter.

 

I had to cut a #2 welding cable last week. My son-in-law suggested using a hand-held pipe cutter, the one used for cutting copper pipe. Worked like a charm, just had to be careful and not go too deep. I made a perfect cut in just a minute or two.

 

Here's a cheap version of the above cable cutters. If you only need to use them a couple of times, $10 and you're done! They worked great for cutting 1/0 cable in my car.
https://www.harborfreight.com/10-inch-cable-cutter-40507.html

 

I have one of those cutters posted above by swade41, I've always thought it was for cutting rubber fuel line/heater hose...which it is a wonderful tool for. I'll have to try it on some cable.

 

The HF cable cutters are fine if you just cut an occasional copper cable. I'd bet even money that my brothers who are both journeymen electricians both have Klein 6305 cutters in their tool kit though.
Actually for those of us who do maybe two cables a year using what you have on hand that does a clean job has it's merrits.

 

No problems for me...

 

Cable cutters for the win - & a clean cut. I use an Exacto(modeling knife) w/a new sharp blade to lightly cut the insulation, 'till I can pull it off w/o cutting the fine wires & a proper mechanical(mine uses a heavy hammer to drive the crimping) crimpers made for cable, for the lugs. If you're using lead-ends, I found using the smooth slip-ons & an A/C hose-fitting-crimper works well. I like to use a bit of super-lube to coat the wires & terminal, then cover the end w/the heavy-duty glue-impregnated shrink tubing. Almost bullet-proof, resists salt wicking, if you actually use the car in less-than-perfect weather.
Marcus...

 

I have all shown above & some including hydraulic handheld crimpers...
But not needed ,
A simple pair of Dike cutter will do .

This Cheap crimper works well
For $35
&
Also YOU KNOW !
some time you need to think out side of box when you do a Road call in
Truck stop parking lot
Flip Noise K W , driver shook his Head

 

Thanks. I am not sure what the exact length is yet, still routing cable, but we should meet up for coffee sometime.

 

These do work great, but if you get some, keep them hidden away and don't lend them.
We have a couple of them at work but inevitably some ***** uses them to cut barbed wire or wire rope or something, and ******s them.

 

I have always used a hammer and chisel. Cheap and always makes a clean cut.

 

I have several nice electrical cable cutters, so I'm spoiled. But for $10 you can't beat these Harbor Freight cable cutters. One quick cut and you're done!
https://www.harborfreight.com/10-inch-cable-cutter-40507.html

 

Put a few wraps of tape where you want to cut and use a fine tooth hacksaw blade. Doesn’t need to be perfect, you're putting ends on it anyways right?

 

Yup I use 2 zip ties and cut in between them with my band saw.

 

Those are exactly what I was going to say. I love my pair and in fact I resist using them for misc stuff because they are so good at the big stuff I don't want to risk them on a bunch of little wire. But then I have a great pair of Knipex Dikes for the stuff smaller then 6ga

 

It's been a while since the last time I made cables, but I recall working in a dab of bulb grease with a chip brush after cutting and t******* the outer insulation..... then crimping the end lugs and finishing up with heat shrink tube.

 

What's bulb grease?

 

Dielectric grease used on electrical connections to seal out moisture-I'd guess