ProCraft Battery Cables - Quality

ProCraft Battery Cables are made from only the highest qualitly products.

Tin Plated Copper Strand cabling is the standard in the aviation and commercial industries. Copper has stood the test of time and performed exceptionally well, particularly, in high vibration applications. (Think rubber engine mounts). 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 insulators. Our cables are rated at 600V with a temperature operating range from 5C (-67F) to 155C (311F).

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 multi-ton hydraulic crimping tool.  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.

All ProCraft Cable crimps are protected with two layers of heat shrink. The first layer has an adhesive lining. This effectively seals the 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.

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.

We don't offer Aluminum Cables.  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.  Considering the relatively short runs used in small aircraft, cars, boats, and other personal vehicles, the larger cross section of aluminum cable, difficulty in routing, lower strength, high cost, and the environments these cables are used (high vibration), we don't think Aluminum cabling makes any sense. As a result, we don't offer it.

ProCraft Battery Cables - Quality