Battery cable connector sizes

klanel

I see about 4 different bolt sizes on my cart for the power wiring.

The center post on the f/r switch are probably somewhere around 1/8" because a 3/16" eye is way to large. (And this is supposed to be heavy duty??)
The outer post are about 1/4" (Actually this F/R switch doesn't look any more heavy duty than the original one but that's what it was sold to me as.

Looks like the motor and controller are about 5/16"

And the solenoid is 3/8"

My question is whether some of you are using closely fitted connectors or if they are oversized holes. The connector hole sizes I've found for 2 awg cable are 3/16", 1/4", 5/16", 3/8" and 1/2".

Other question, is there some sort of lug tap that will allow me to piggyback control wiring to the controller? I want to secure a 2 awg battery cable to the controller (say B+) with a 5/16" bolt but want to make some other connections to the same point. I am trying to get away from stacking connectors under the same bolt.

BGW

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Sergio

On a stock FNR, the swivel posts are held in place by:
#10-24 X 1/2 screws, so they are #10 posts or 3/16"

The other F&R wires are held in place by:
1/4-20 X 5/8" screws, so they are 1/4" size

Battery, Motor, Controller and most Solenoids are 5/16"

Heavy duty Solenoid and Reversing Contactors are 3/8"

The Lugs should be the correct size for the bolts in order to have the most current transfer surface contact with the terminal.

The screws are just fasteners, they are not intended to carry current.

If You need to stack 2 Lugs in one terminal, if the terminal is a "Bolt-Through", put one Lug in each side ("Flat" profiles towards the terminal).

If the terminal is a "Pad", turn the first Lug upside down so the "Flat" profile is pointing up and stack the second lug with the "Flat" profile point down on top of the first.

Always put the highest current capacity Lug first when stacking Lugs.

klanel

Sergio, thanks for the info!

scooterman

That should be a sticky, usually you see the doubling up on the controller lugs, it can be tight and the screws seems like they could be a little longer, also when doubling up it can be a fine line of how tight you should go without damaging the threads or controller connection.