Has anybody ever used heavy guage jumper cables as battery cables and are there any repurcussions for doing so? Where can I find and what would I need to solder the spade terminals to those cables so they won't arc?

Best way is to put the terminal in a vise, goop it up with flux, heat and stick the wire in and then apply solder. Heat shrink tubing is a good thing to use as well, it looks sharp.
Make sure those cables are big enough, most guys use old welding cable.

Do a search on this, there have been several threads about upgrading the battery cables in our trucks. I re-did mine with #00 welding cable and top terminal batteries a few years ago. As a side note, welding cable and clamps make the best jumper cables *ever*.

Terminals can be had at a welding supply house or NAPA.

there is also a speicalized crimper you can buy for doing battery cables as well, they range from $60-150.00 (depending on brand & quality). battery cable & end goes in, and you wack it with a hammer on a hard surface. I usually crimp, then solder. I would avoid using booster cables though, new welding cable is probablly cheaper :)

-Jeff

Best way is to put the terminal in a vise, goop it up with flux, heat and stick the wire in and then apply solder.

I have to disagree with your soldering method; if you heat just the terminal and then stick the wire in, the solder will melt against the terminal but will make a very, very weak connection to the wire. You have to heat both the wire and the terminal together, get the temperatures of each past the solder melting point, and then add your solder. Let them cool as slowly as possible to get the best connection.

You're correct Trios. Keyboard slipped into gear while the brain was idling. D'oh!

they should be crimped. solder can be added, but don't expect the solder to hold if the cables get hot from a hard crank

they should be crimped. solder can be added, but don't expect the solder to hold if the cables get hot from a hard crank

Electrical solder melts at roughly 220 degrees Celsius, or around 430 degrees Fahrenheit. If your cables are getting anywhere near these temperatures, you have a VERY serious issue with your electrical system. Cycling solder between ambient and 100 Celsius won't cause any issues, and that's about the highest I would expect any reasonably sized cable to get on a long, hard crank.

http://custombatterycables.com/index.htm

I used 00 gauge cables on my burb and I can say for sure that it doubled my starting RPM and made starting much, much easier. If the engine is warm I can bump the starter for 1/10 sec and it will be running. Cold and it takes a few cranks, a few more if its cold out and unplugged and hasnt started it in a week or so.