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Unread 10-29-2015, 06:36 PM   #51
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Default Re: Making my own cables

You are better off putting everything own its own lug or ring terminal.

That way all you cables and wires have their own crimp.

When you put multiple cables/wires on a single stud, make sure the ones that carry the most current goes first.

For the Controller B- connection:
Pack Negative with lug upside down (flat profile pointing away from the controller).
10 ga cable from OBC.
10 ga cable for accessories.
Bolt Head.
For the Controller B+ connection:
Positive From Solenoid with lug upside down (flat profile pointing away from the controller).
Cable going to Motor A1 terminal.
Bolt Head.
For the Solenoid:
Pack positive cable with lug upside down (flat profile pointing away from the solenoid).
Positive Wire for harness.
Nut.

For any battery post the new 2ga cable goes first then stack the other ones on top.

You do not need to replace the wires going to F1 and F2.

Always use 2 wrenches on the Motor terminals.
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Unread 10-29-2015, 06:52 PM   #52
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Default Re: Making my own cables

So the green and white wire from the motor replace, nothing else from back there is replaced?
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Unread 10-29-2015, 06:56 PM   #53
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Default Re: Making my own cables

Correct, the F1 and F2 wires (Blue and Orange) don't carry much current and don't need to be replaced.
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Unread 10-29-2015, 07:18 PM   #54
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Default Re: Making my own cables

To make my own obc Rod, what type of "sleeve can I make myself that will work? Would a piece of rubber tube work?
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Unread 10-29-2015, 09:24 PM   #55
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Default Re: Making my own cables

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Originally Posted by dc_customdesign View Post
To make my own obc Rod, what type of "sleeve can I make myself that will work? Would a piece of rubber tube work?
I used quality 3m electrical tape and wrapped a few times around the mid section of the bolt and is working great so far.
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Unread 10-29-2015, 09:57 PM   #56
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Default Re: Making my own cables

I agree, a few turns of electric tape on about 1 inch on the center of the stud is all You need.

It is not for any electric insulation, it is simply to keep the stud threads from being abrasive to the "potting compound" used inside the OBC hole.

Lowes sells the USBrass 5/16 - 3 1/2" bolts and nuts in their "specialty hardware" section (much better electric conductor than galvanized steel), or You can always get a 5/16 brass toilet flange bolt, but I am not sure the quality of the brass alloy used in those bolts.

I put all of the nuts (4) on the bolt and lined them up even, placed the assembly on a bench vise squeezing the nuts and cut the bolt head with a hack saw.

I then "locked" the two nuts furthest from the head together, held them with a wrench and ran the other two out of the end I just cut in order to clean the threads.

I had to grind the large washer on the battery compartment on my stud to look like a capital D so it would fit flush against the OBC.

Here is a picture of all the pieces needed
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Unread 10-30-2015, 01:21 PM   #57
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Default Re: Making my own cables

Quote:
Originally Posted by Sergio View Post
What tinned lugs are you referring to?

The ones I am talking about are pure copper with a Tin plating for corrosion resistance.

I never heard of lower content copper lugs, unless they are from Chinese manufactures and not quality lugs like FTZ industries.

The Tin plating is an extra process applied over the lug so it does not make sense that it would be cheaper.
I am talking about the same terminals. You can contact any manufacturer and will find the same thing I stated. I found it hard to believe myself, but after asking 4 different companies who manufacture in America welll, it is what it is. I've made thousands of cable sets and thus have used tens of thousands of lugs, and it has always been that way. I even tried to convice the people that it had to cost more to coat a copper lug given it required another step, to no avail.
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Unread 10-30-2015, 02:21 PM   #58
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Default Re: Making my own cables

I think google works the same for everybody.

I put tinned lug in and search price. Then I put copper lug in and search price.

I easily find copper lugs FOR 20% LESS than tinned copper lugs so why are we listening to this BS?
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Unread 10-30-2015, 02:41 PM   #59
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Default Re: Making my own cables

Quote:
Originally Posted by scottyb View Post
I think google works the same for everybody.

I put tinned lug in and search price. Then I put copper lug in and search price.

I easily find copper lugs FOR 20% LESS than tinned copper lugs so why are we listening to this BS?
Now I understand a great deal of the business I get from here and the reasons they give me. It seems everytime I show you something or tell you something you simply must try negate it. So why don't you ante up and post your super cheap copper and tinned copper lugs. I could sit here and post the prices listed by Temco Industrial or any other manufacturer all day long and it wouldn't seem to do you any good. And while you're at it, please be sure to explain to the people the cost differential in 2awg and 2/0, 4awg and 4/0 etc.

And just for good measure here is a sinlge example
http://www.temcoindustrialpower.com/...ls/RT3631.html
http://www.temcoindustrialpower.com/...ls/RT3632.html

This can be further seen on Google, Amazon and eBay with relative little effort in searching.
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Unread 10-30-2015, 04:25 PM   #60
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Default Re: Making my own cables

I see you carefully chose the links you provided.

If You follow this link where a single product is displayed, You will notice the 'Tinned' lugs cost more than plain copper for just about every quantity.

http://www.temcoindustrialpower.com/...Cg.o&c=0004003

So I just called the 877 number on the page and talked to the sales person.

His first answer was that Tinned products cost more because they are a better product.

I then pointed out that their web page shows differently for quantity 50 and gave him the item numbers.

He put me on hold to talk to his manager.

He came back and said that is how "they get their lots", which leads me to believe they simply re-distribute those parts and not actually make them.

I again looked at the webites that sell the top brands and they all charge more for Tinned lugs.

I will point out something I just noticed looking at your listings on eBay and as a warning to users making their own cables.

When working on high current systems, Properly Sized Connectors are critical.

You are selling cables with 3/8 lugs to go on golf Carts 5/16 battery posts????

That would be rejected in any installation that requires inspection and it would immediately question your qualifications for doing the job.
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