On Oct 27, 4:55*pm, "T.Alan Kraus" wrote:
Scenario facts: *a piece of stranded copper battery cable about 3.5"
long with two soldered connectors at each end, used for ground
connection on a motorcycle battery. The cable broke in the middle with
what looks like a stress fracture. Cable was flexed many times, every
time battery had to be taken out or when battery had to be disconnected
for electrical tests or electrical modifications to motorcycle wiring.

Son contends it is the fault of soldering connectors onto cable, which
heat stressed the cable. I think it is copper work hardening when
flexing cable, thinking that heat if anything (maybe to low) would help
anneal copper.

Your opinion welcome.
cheers
T.Alan


You may find the flexing and breaking is caused by the vibration from
the engine work hardening the copper. Just because you can't see the
flexing doesn't mean it is not there. You need to encase the new cable
with some type of heavy insulation which will dampen the vibrations.
Perhaps instead of stranded battery cable, use a short length of heavy
welding cable. The copper strands are quite small and will not vibrate
near as much and the heavy insulation will dampen the vibration even
more.

Paul