Started my install last weekend, slow going. But wanted to get my Big 3 done today. Had 1/0 Knu ready to go along with 1/0 terminals and solder slugs. I did a 4 AWG overlay for the alt B+ cable last weekend and soldering went fine.

But, I'm finding it is nearly impossible to solder 1/0 cable. One, the Knu wire sheath melts away to easy when tinning the leads which you absolutely have to otherwise there is too much of a cold sink if you simply try to push your wire into the terminal right after the solder slug melts. Even with tinning, there is still too much of cold sink which is cooling my solder before I can push the wire into the terminal. Second, Knu wire is PIA since it is oversized which is not helping.

I went thru 8 terminals and tried a few different things, but I'm giving up. I am using a torch so getting plenty of heat and I'm an electrician by trade so understand why it is not working.

How do you guys terminate your 1/0 for grounding - set screw, compression terminal, crimp w/ tool, crimp w/ vise, or crimp w/ hammer/chisel? Thanks.

 

I crimp my 4 gauge and bigger with a vise. I pinch it at the middle of the crimp terminal.
The only problem I've run into is when a wire is in the car already... in those situations I've had to get terminals or fuse blocks that have set screws.
I've seen those solder plugs but that always seemed like more work that it's worth. I like to do things right but as easy as possible.

You could also take your cables into a battery store already cut to length and have them crimped for you. Maybe pay a few bucks and save some frustration.