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Old 11-27-2007, 02:57 PM   #409 (permalink)
MetroMPG
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Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
Posts: 22,530

Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 54.46 mpg (US)

Even Fancier Metro - '14 Mitsubishi Mirage top spec
90 day: 70.75 mpg (US)

Appliance car Mirage - '14 Mitsubishi Mirage ES (base)
90 day: 62.14 mpg (US)
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08-30-2007, 03:40 Pm

I snuck out and made another couple of test lugs & connections with more judicious use of the heat as suggested.

Revised process:

- cut & trim cable
- flux & tin cable bottom 1 cm
- while cable cools, make lug: cut copper pipe, heat & flare open end, flatten the other end
- flux & fill open end of lug about half way up with molten solder
- briefly heat tinned cable end, add a bit more heat to lug & insert cable in molten solder

The solder that gets pushed up out of the lug when I insert the cable isn't making a good join (cold joint) up high around the "collar" of the lug, but I dissected my last attempt and it looks OK deeper in the lug.

But I'm waiting to hear back from the forklift place. Which way we'll go from here depends on how much money they want to sell us "proper" lugs (and if they'll lend us their crimper).

I'll post some pics of my lug attempts later.
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Project MPGiata! Mods for getting 50+ MPG from a 1990 Miata
Honda mods: Ecomodding my $800 Honda Fit 5-speed beater
Mitsu mods: 70 MPG in my ecomodded, dirt cheap, 3-cylinder Mirage.
Ecodriving test: Manual vs. automatic transmission MPG showdown



EcoModder
has launched a forum for the efficient new Mitsubishi Mirage
www.MetroMPG.com - fuel efficiency info for Geo Metro owners
www.ForkenSwift.com - electric car conversion on a beer budget
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