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Wire and Cable Blog

Category: Compression Lugs

Crimping Burndy® Compression Lugs to Flexible Cables

Crimping Burndy Compression Lugs to Flexible CablesCompression lugs and the crimping tools used to attach the two are very important to have a good connection. The welding cable needs to be cut to the right length first of all. Then it is important to make sure you are using the proper tools to attach the compression lug to the cable. There are machines that will do this but some people may prefer to crimp the lugs themselves. There are hand help tools that will let customers do this. It is also important to look at all the options for hand held crimping tools.

Cut Wire to Length

Wires can be cut in two ways, either by machine or by hand. Machines can cut the wire to length and strip the insulation off each end, which prepares it for crimping the lugs. If you are cutting wires by hand you need to make sure that you leave enough extra length so the wire can be stripped of its insulation and have the compression lug crimped on the end and still have the wire or cable be the correct length.

Buy Burndy® Lugs

The Burndy® compression lugs are made to last. The compression lugs come in either long or short barrel. Customers can also choose a lug with either one or two bolt holes. The long barrel lugs will give customers an added crimp onto the welding cable. Adding another crimp onto the cable gives the customers a more secure connection. If the welding machine you are attaching the cable too vibrates a lot and there is going to be excess tugging and pulling of the machine around the shop then look at a compression lug with two bolt holes. This will give customers a sturdier and longer lasting connection to the welding machine.

Crimping Tools

Hydraulic compression tools are commonly used to crimp lugs to welding cables.  The hydraulic crimping tools provide 6 tons of force when crimping the lugs onto the welding cable. It also has other features that allow it to crimp lugs that are in tight areas. Each Lug requires a certain tool and dye to compress the lug to the cable. There are a variety of different kinds of crimping tools that a customer can purchase. There are the mechanical, hydraulic, battery powered, or even remote power compression tools. Each one of these tools is different so make sure you have done your research on each to find which tool will be best for what you need to be done.

The Burndy® crimping tools work best when attaching a Burndy® compression lug onto a welding cable. This is because each different cable or lug will need a specific kind of tool to crimp both together. Make sure you look into all of your crimping tool options before purchasing one. You don’t want to end up with one that won’t get the job done right the first time.

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Written by: WesBell Electronics

Crimping Two Hole Lugs to DLO Cable

Two Hole LugsDLO cable is thick and heavy because it’s an industrial power cable used in tough environmental conditions. It provides portable power to large equipment on job sites without power. It has a dual rubber jacket so that it can be run over by trucks and still perform just as well.

The introduction is to make you realize why a two hole lug is common for DLO cables. Long barrel lugs are also popular with the diesel locomotive cable because they provide a more secure connection. Long barrel compression lugs are crimped twice with a hydraulic tool so that the lug and the cable are solidly connected. Likewise, two hole compression lugs are bolted twice so that equipment vibration can’t shake the connection loose.

Short barrel and one hole lugs are used for smaller equipment within garages and shops. They also use a smaller cable because there isn’t as much power in smaller machines. Welding cable is a good fit for projects under 600 volts. DLO cable is rated for 2000 volts due to its tough construction.

All of our compression lugs are manufactured by Burndy®.

See Burndy® Products here >>

One Hole Welding Cable Lugs Information

One Hole Compression LugsIn order for welding cable to deliver power it has to have two secure connections via compression lugs. One hole compression lugs with a short barrel are the most basic and affordable. They support applications with the least amount of vibration due to their short barrel, single hole and single crimp design.

If you need to support additional vibration you can upgrade to a long barrel or two hole lug. The long barrel allows for two hydraulic crimps to secure the lug tightly to the cable. Or you can opt for a two hole compression lug that’s bolted twice to its piece of equipment.



Short Barrel Compression LugsWelding cable lugs get cheaper as the quantity increases but you can purchase a single lug at a time on our website. Each gauge size of welding cable has about 4-5 options for one hole lugs. First, you’ll choose between short barrel and long barrel. Then you’ll have to choose the bolt size which range from 1/4” to 5/16”.

One hole lug pricing is available here >>


For Flexible Cables

The lugs throughout the welding cable section of our website are fit to welding cable specifically. The lugs are designed to fit better with flexible cables than nonflexible cables. You can notice it in the part numbers if the end in “FX” for FLEX LUG.

All of the lugs sold on our website are manufactured by Burndy®