Solar PV advice

[Countrypaul]

If they sometimes lable 25mm2 cable as 35 then maybe they are supplying 25mm lugs marked as 35 to match the iffy cable?

A photo might help.

[Moxi]

check the measurements - you may have been miss supplied cable / lugs

Moxi

[Richard77]

I think they fit....

Probably just poor technique on my behalf!

[MrPablo]

If you've already removed the insulation, you could try to compress the strands with a cable tie and then slide the lug on, followed by cutting the cable tie off and sliding home.

[Richard77]

Inner diameter of the lug seems to be 35mm and diameter of copper in the cable seems closer to 40mm inside the insulation. Obviously it will compress a little bit too. (ignore my measurement... Brain freeze)

Don't know.... Just seems too small to get on without fraying loads of strands.

[Richard77]

If you've already removed the insulation, you could try to compress the strands with a cable tie and then slide the lug on, followed by cutting the cable tie off and sliding home.

Thanks MrPablo...

I was actually looking for some cable ties as saw a YouTube vid doing the same...

[pudding]

I found the key when doing mine was getting all strands just inside the flare before trying to push the cable in, then once they were just inside the flared section, they compressed to fit inside as you push it in. The strands look a little frayed there though and wider than they need to be? This was mine before putting inside the lugs-

[Richard77]

Cheers pudding...

Yeah mine are a little frayed due to the "practising" hehe

[MikeNovack]

You'd probably need another 50% of end with insulation removed, but the you could use a small modern (screw) "hose clamp" to tightly squeeze those wires together. Once the protruding end started into the flare remove the hose clamp by really undoing it. The old type (that used special pliers to squeeze the ends clamp so would "open" not sure if you could remove.

[Stinsy]

You'd probably need another 50% of end with insulation removed, but the you could use a small modern (screw) "hose clamp" to tightly squeeze those wires together. Once the protruding end started into the flare remove the hose clamp by really undoing it. The old type (that used special pliers to squeeze the ends clamp so would "open" not sure if you could remove.

I've seen this "trick" done with a cable tie before...