Downsizing my Power Cables on a DS

Hunter450 · 09-10-2016, 10:21 AM

Now don't get excited, a previous owner of my cart put 2/00 cables between the batteries and to the solenoid and that's was it. I'm making new cables with 2ga welding cable with tinned copper connectors crimped and done right. My question is I'm want to replace the 6 ga ground wire from the pack that goes thru the OBC with better cable. The 2ga cable I have will almost go thru the OBC opening but not without lubrication. Will it affect anything if I apply some form of lubricant on the 2 ga cable? Would it be the end of the world if I used smaller cable? My jury is still out on the brass stud thru the OBC. Any suggestions?

Thanks

teecro · 09-10-2016, 10:27 AM

Would it be the end of the world if you used smaller cable in that one spot? NO but that one cable will cancel all the benefit of the larger cable...

Grease that cable up with some Vaseline and push it through.

Or use a 5/16" brass toilet bolt and make a pass-through stud....

Just don't enlarge the hole as it is risky... I did and passed many others tried and failed....

09-10-2016, 10:41 AM

Quote:

Originally Posted by scottyb

The main negative cable goes from the battery pack to the controller B- terminal.... this cable goes through the OBC as shown.

Cut the old cable end off to remove it.

Install the stud through the computer in the hole where the cable was.
Now install your 2 new cables that go from the battery main - to the OBC stud and from the other side of the OBC stud to the controller B-

Volt_Ampere · 09-10-2016, 11:50 AM

It is NOT true that one small cable cancels the benefit of the larger cable. It is the sum of all the cable resistance that determines the cable loss. Many use a Stud and nuts to cable through the OBC as described above.

Swan · 09-10-2016, 11:56 AM

i went with the stud though the obc when i did my 2 ga.

scottyb · 09-10-2016, 12:02 PM

Quote:

Originally Posted by Volt_Ampere

It is NOT true that one small cable cancels the benefit of the larger cable. It is the sum of all the cable resistance that determines the cable loss. Many use a Stud and nuts to cable through the OBC as described above.

Why be argumentative. It is common knowledge that smaller conductors pass less potential than larger conductors. You can calculate the sum loss of a combination of conductors but the physics remain facts.
Size matters.

Volt_Ampere · 09-10-2016, 12:16 PM

I am being factual. If you replace half of your cables with much larger conductors, you get half of the benefit of replacing all of them. It is misleading to say that one piece of smaller cable negates the benefit of upgrading to larger cables. Of course it is better to upgrade all of them.

jakesnake27 · 09-10-2016, 01:23 PM

I've always heard that it works the same as the 'chain is only as strong as its weakest link' theory. Meaning if you have only one 6 gauge cable and the rest 2 gauge, it would be the same as having all 6 gauge cables. If Volt_Ampere is correct, I find it fascinating...

scottyb · 09-10-2016, 01:37 PM

You are both right.

Want to test it out string out a few hundred feet of heavy extension cord and plug a power hungry tool in. Now replace one section of the cord with significantly smaller cord and run the tool again. This will decrease amperage delivery & lower tool performance. Your cart is the same

Hunter450 · 09-10-2016, 02:10 PM

All is good, I slicked up the 2ga welding cable and wala.... it slipped right on thru. This is addicting!

Thanks guys!

09-10-2016, 10:21 AM	#1
Hunter450 Gone Wild Join Date: Sep 2016 Posts: 515	Downsizing my Power Cables on a DS Now don't get excited, a previous owner of my cart put 2/00 cables between the batteries and to the solenoid and that's was it. I'm making new cables with 2ga welding cable with tinned copper connectors crimped and done right. My question is I'm want to replace the 6 ga ground wire from the pack that goes thru the OBC with better cable. The 2ga cable I have will almost go thru the OBC opening but not without lubrication. Will it affect anything if I apply some form of lubricant on the 2 ga cable? Would it be the end of the world if I used smaller cable? My jury is still out on the brass stud thru the OBC. Any suggestions? Thanks
Hunter450 Gone Wild Join Date: Sep 2016 Posts: 515

09-10-2016, 10:27 AM	#2
teecro Gone Wild Join Date: Jun 2014 Location: Sunset Bay, TN Posts: 2,390	Re: Downsizing my Power Cables on a DS Would it be the end of the world if you used smaller cable in that one spot? NO but that one cable will cancel all the benefit of the larger cable... Grease that cable up with some Vaseline and push it through. Or use a 5/16" brass toilet bolt and make a pass-through stud.... Just don't enlarge the hole as it is risky... I did and passed many others tried and failed....

09-10-2016, 11:50 AM	#4
Volt_Ampere Gone Wild Join Date: May 2012 Location: Rio Verde, Az Posts: 7,170	Re: Downsizing my Power Cables on a DS It is NOT true that one small cable cancels the benefit of the larger cable. It is the sum of all the cable resistance that determines the cable loss. Many use a Stud and nuts to cable through the OBC as described above.

09-10-2016, 11:56 AM	#5
Swan Cave Dweller Join Date: Apr 2013 Location: Always On The Move Posts: 22,216	Re: Downsizing my Power Cables on a DS i went with the stud though the obc when i did my 2 ga.

09-10-2016, 12:16 PM	#7
Volt_Ampere Gone Wild Join Date: May 2012 Location: Rio Verde, Az Posts: 7,170	Re: Downsizing my Power Cables on a DS I am being factual. If you replace half of your cables with much larger conductors, you get half of the benefit of replacing all of them. It is misleading to say that one piece of smaller cable negates the benefit of upgrading to larger cables. Of course it is better to upgrade all of them.

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09-10-2016, 01:23 PM	#8
jakesnake27 Gone Wild Join Date: Aug 2009 Posts: 14,245	Re: Downsizing my Power Cables on a DS I've always heard that it works the same as the 'chain is only as strong as its weakest link' theory. Meaning if you have only one 6 gauge cable and the rest 2 gauge, it would be the same as having all 6 gauge cables. If Volt_Ampere is correct, I find it fascinating...
jakesnake27 Gone Wild Join Date: Aug 2009 Posts: 14,245

09-10-2016, 01:37 PM	#9
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Downsizing my Power Cables on a DS You are both right. Want to test it out string out a few hundred feet of heavy extension cord and plug a power hungry tool in. Now replace one section of the cord with significantly smaller cord and run the tool again. This will decrease amperage delivery & lower tool performance. Your cart is the same

09-10-2016, 02:10 PM	#10
Hunter450 Gone Wild Join Date: Sep 2016 Posts: 515	Re: Downsizing my Power Cables on a DS All is good, I slicked up the 2ga welding cable and wala.... it slipped right on thru. This is addicting! Thanks guys!
Hunter450 Gone Wild Join Date: Sep 2016 Posts: 515

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