Frequently Asked Questions
What kind of cable do you use?
Tin Plated Copper Strand cabling is the standard in the aviation and automotive marketplace. Copper has stood the test of time and performed exceptionally well, particularly, in high vibration applications. (Think rubber engine mount applications). The Mil-Spec cable we use (Mil-W- 22579/16-XX) provides exceptional performance and resistance to corrosion. The Tefzel insulation provides "vault-like" protection of the conductors, and has many desirable mechanical properties not found in other conductors. Our cables are rated at 600V with an operating envelope ranging from 5C (-67F) to 155C (311F).
What kind of Lugs do you use?
Our lugs are 100% copper with a tin plating. The tin provides for corrosion protection, as well as being an excellent conductor. The copper provides high conductivity, high strength (resistance to tear-out), and performs exceptionally well in high vibration applications. Crimping copper lugs onto copper conductors provides an electrically sound and very strong cable assembly. The fused connection is as strong as the cable itself. ProCraft Battery Cables are assembled using a commercial grade electro-hydraulic multi-ton crimping tool with engineered "hex" dies. Using "hex" dies provides several advantages, most important, you get a perfect crimp every time. Using dies prevents over-crimping (crushed conductors), poor conductivity, and loss of strength. By applying tons of force in six different directions, "hex" dies give even compression (contact) all the way around the lug. It's no surprise that "hex" crimps are the preferred crimp in the commercial electrical industry.
What is the heat shrink for?
All ProCraft Cable crimps are protected with two layers of heat shrink. The first layer has an adhesive lining to seal lug to the cable insulation, preventing oxygen, moisture, filth, and chemicals from reaching the conductors. The second layer provides for identification (Power/Ground) and performs better in high temperature environments. These attributes make it a good choice for use in compartments offering "hostile environments" such as engine compartments, wheel wells, gear boxes, etc.
Can't I build my own battery cables?
Sure you can but most builders don't have specialized equipment or Mil-Spec materials on hand to do so. Cables built with a vice, a hammer on the garage floor, or a torch & solder, may have poor mechanical connections, resulting in high resistance. Resistance in high current circuits will ALWAYS lead to corrosion, poor performance, and a lot of HEAT! These are undesirable traits in applications such as farm tractors and they are totally unacceptable, and potentially unsafe, in aviation.
Which is more expensive, ProCraft Battery Cables or Do-It-Yourself cables?
ProCraft Battery Cables are built by professionals using multi-ton hydraulic crimpers and specialized hex-dies. If you'd like to see the quality of our crimps and lugs, check out the "pull test" pages. Our exceptional crimps, cable, shrink wrap process, and lugs result in outstanding performance (mechanically and electrically) over the long haul. Of course, they're built to YOUR specifications. You could probably build a quality cable, too, but you'll spend much time and effort tracking down a spool of cable, lugs, and then there's the hydraulic press and dies. Or were you going to use a hammer? Savings is relative to the end product. We believe ProCraft Battery Cables are a great value and our customers seem to agree.
Which is more reliable, ProCraft Battery Cables or Do-It-Yourself cables?
Cables that carry high current must be of high quality, no exceptions. For the reasons stated above, we think ProCraft Battery Cables are not only an excellent value but will perform better than anything built on a typical workbench. The materials you join, and how you join them, are critical to a quality end product. We take a lot of pride in our work and consider the final product our testimony.
Why don't you offer that "Fatso-Fancy" Aluminum Cable?
Piper tried using aluminum battery cables and it was a disaster. Today, most of those systems have been replaced with tin coated copper conductors. Airbus and Boeing have good reason to utilize aluminum cable when large conductor lengths can be hundreds of feet in length, but in small aircraft, there is no advantage. Here are a few of our observations:
- If using aluminum instead of copper, the aluminum will be nearly twice the diameter of the copper. As if battery cables aren't difficult to run as is, making them even fatter doesn't ease installation.
- Aluminum does not do well when flexed. Our engines are on rubber mounts and they move around a lot. Copper cable has proven itself in small aircraft over the past 6 decades. Copper is reliable, strong, and very durable. Aluminum doesn't have a comparable track record in small aircraft applications.
- Aluminum cables are expensive. You could easily pay as much for the parts (if you can find them) as you would for a complete ProCraft Battery Cable.
- Crimps on aluminum cables are not as strong as those copper cables.
- Weight savings are negligible. Using a 6 foot aluminum cable instead of a 2AWG copper cable will save you about 3 or 4 ounces. It is doubtful that any small aircraft would realize a weight savings of more than 12-16 ounces in total using aluminum cables.
In summary, weight is the only advantage aluminum has over copper but considering the short runs used in small aircraft, the larger cross section of the aluminum cable (requiring larger bend radius and pathways), higher cost, and the high vibration environment, we don't think it makes sense. As a result, we don't offer it.
Are the "default" wire and cable sizes specified in the Order Form sized appropriately for my airplane's electrical system?
ProCraft schematics (available here) were developed from actual flying aircraft. The "default" AWG sizes shown on the Order Form represent the wire sizes used in a particular aircraft we examined, or in some cases, had a hand in building. This does not mean they are suitable for YOUR aircraft. YOU must determine what size cable is required for your aircraft and make the appropriate entries/changes on the Order Form. We are not in the schematic building business and only offer these as reference for helping you order ALL the required cables for your installation. Our schematics are NOT a recommendation of what size, how long, or what lugs should be installed for YOUR application. If you need assistance in determining proper cables sizes we highly recommend checking with your aircraft designer or you EAA Technical Counselor. Other options are to check out Bob Nuckoll's Aeroelectric Connection and/or the FAA's Acceptable Methods, Techniques, and Practices (aka: AC4313) as references when planning the electrical system for your aircraft. Both are very valuable texts.
How long will it take to get my ProCraft Battery Cables?
We ship ProCraft Battery Cables on the 1st and 15th of each month. If we get your order on the 14th, we'll do our best but can't make any promises it will go out the next day. We batch orders to make the process more efficient and organized. In most cases, builders don't need cables overnight. If you're just putting cables on the airplane you are not likely to be flying the next week so we don't think we're holding anyone up by shipping twice monthly. If you're really in a "pickle", shoot us an email and we'll see what we can do. You can write to us at: CustomerCare@SafeAir1.com
Why don't you accept credit cards for my ProCraft Order?
By eliminating credit card company fees, SafeAir1 is able to better control expenses. ProCraft Battery Cable orders are processed and shipped twice monthly. Since ProCraft customers will be mailing in the order form to us, we feel there is little inconvenience associated with payment by check (personal checks, bank checks, money orders, are all acceptable).
In addition, SafeAir1 has always viewed our customer's checks as "cash". We don't wait for checks to clear before shipping product so no delay will be imposed for payment by check.
How are ProCraft Battery Cables shipped?
U.S. Postal Service Priority Mail.
Do you ship outside the United States?
Not yet, but we expect to soon.