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DIY Power Cable Advise Needed

Ok all you DIY junkies. I am trying to put together a power cable using double runs of 10AWG wire. The problem is that all of the connectors (Wattagate, Hubble, Marinco, etc) only accept one 10AWG wire. So how would you terminate two 10 AWG wires into one. So far the best way is to just solder them together and wrap with Teflon tape and heat shrink. There must be some better way. I am looking for advise from somebody who has done this kind of thing before. Is there a high quality connector that can be used to joing two 10AWG wires into one? (The wires are stranded - not solid). Any suggestions would be appreciated. I am trying to stay away from the run of the mill "butt" connectors. One of the local cable houses here says they would hit it with a 50 Ton press and form it using a "cold" welding technique if it were done there. This really doesn't help me though. Thanks - Dan.
dan2112
7 responses Add your response
dekay's avatar
dekay
5,346 posts
 
Maybe you could get by with a 25 ton press.
redkiwi
1,092 posts
 
Dan, you are barking up the wrong tree if you think good power cords are merely made by using thick conductors. Cable geometry, shielding and dialectrics are more critical by far.
leafs
414 posts
 
One 10 AWG is more than you need.Good pure conductors and and shiedlding and dialectric are more important.
redkiwi
1,092 posts
 
Leafs, the geometry is also very important - much of the effect of good power cables is due to how the geometry achieves common mode rejection (CMR). CMR is relatively easy with two cables, but this changes when dealing with three and adds complications that add cost - and different designers start developing different strategies.
dan2112 OP
144 posts
 
Suffice to say the cable is shielded and braided. I was just worried about crimping vs soldering in this application. Without going into details about the cable I was just wondering if somebody else has come across a good crimping technology for this size wire. - Cheers. Dan
gmkowal5c1a
91 posts
 
I applaud your efforts in making your own power cable. I bought some #10 litz wire on EBAY for $25 and married it to some hospital grade plugs. The net cost was $40 and it actually sounded better than my buddy's $650 high end power cord. Just goes to show you, it does not have to be expensive to work well.
sgmlaw
76 posts
 
I'm just curious - is this power cord going straight into a standard wall outlet or conditioner? In either case, I'm not sure that a conductor that size is going to add that much unless you're running it into a very high capacity branch circuit (30 amps or greater). Otherwise you're only attaching a firehose to a drinking straw, so to speak.
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