Best way to repair this broken aluminum connector?

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This problem came from my recent modification of my Lincoln ac/dc 225.  Thread here:http://weldingweb.com/vbb/showthread.php?t=148541I put some receptacles on the front to make my leads removable.  After putting it back together, it wouldn't weld.  I finally got some time today to look at it and found the problem.  A lead coming off the lower transformer broke at the terminal.  So now I need to braze it back together.  I have to do this in place and I don't have much room to work from.  Anyone have some suggestions on the best way to repair this without causing more damage? Attached Images
Reply:From a practical standpoint--remove that lead from the machine and install a new end."Brazing" that AL in place???.....not going to happen.Blackbird
Reply:Call a local electrical contractor.  They usually carry that crimp ring on their trucks.  Best   Bob
Reply:If it is a AL solid/wire not a tube(hard to tell from the flash)  just cut so the end is not flared and crimp on a proper copper lug of that gauge size. if is too short you might have to splice in a jumper to make up the length.
Reply:I was hoping to find an option other than removing it.  I'll probably end up with more broken ends if I attempt that... Attached ImagesLast edited by Stainless; 08-09-2012 at 06:45 PM.
Reply:Beat the end flat and drill another hole in it.Thanks,HoboLincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.
Reply:Run down to the hardware store and pick up an aluminum electrical lug. Clean up the end of the tube so it's round and put it on. Tighten good and tight. Fast and cheap. Attached Images
Reply:^^ X2 on what he said.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by forhireRun down to the hardware store and pick up an aluminum electrical lug. Clean up the end of the tube so it's round and put it on. Tighten good and tight. Fast and cheap.
Reply:X3 on the screw down lugsIan TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by forhireRun down to the hardware store and pick up an aluminum electrical lug. Clean up the end of the tube so it's round and put it on. Tighten good and tight. Fast and cheap.
Reply:Originally Posted by mckutzyIf it is a AL solid/wire not a tube(hard to tell from the flash)  just cut so the end is not flared and crimp on a proper copper lug of that gauge size. if is too short you might have to splice in a jumper to make up the length.
Reply:You should get some Aluminum 'anti-oxidizer' coating (not sure what the trade name is) so you keep those connections solid...  Home Depot sells it near those lugs... [I'm assuming the wire is Aluminum]Last edited by WeenerDog; 08-10-2012 at 05:17 PM.Reason: Al wire?
Reply:Thanks everyone.  Saved the day.  Only took a few minutes to smash the end enough with vice grips to slide the terminal over.  Just tested it.. welds again. Sent from my DROID BIONIC using Tapatalk 2 Attached Images
Reply:I'm a sucker for a happy ending.Ian TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by StainlessI was hoping to find an option other than removing it.  I'll probably end up with more broken ends if I attempt that...
Reply:Originally Posted by forhireRun down to the hardware store and pick up an aluminum electrical lug. Clean up the end of the tube so it's round and put it on. Tighten good and tight. Fast and cheap.
Reply:Originally Posted by StainlessJust tested it.. welds again.
Reply:Stainless  -  What else?  Bubble-Pack to the rescue  -  Opus
Reply:Originally Posted by OPUS FERROStainless  -  What else?  Bubble-Pack to the rescue  -  Opus
Reply:Originally Posted by StainlessThanks everyone.  Saved the day.  Only took a few minutes to smash the end enough with vice grips to slide the terminal over.  Just tested it.. welds again.
Reply:Originally Posted by DanTYou removed the Aluminum end before you used the copper screw-down terminal on that, yes?
Reply:you should still apply the anti-oxidant.miller thunderbolt 250vlincoln square wave tig 175 prolincoln idealarc mig sp250everlast tig 210EXTeverlast power plasma 50chicago electric (hf) 130 tig/90 arcchicago electric 90 amp flux wire3 sets oxy/acet
Reply:Originally Posted by WeenerDogYou should get some Aluminum 'anti-oxidizer' coating (not sure what the trade name is) so you keep those connections solid...  Home Depot sells it near those lugs... [I'm assuming the wire is Aluminum]