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Unread 09-12-2016, 05:55 AM   #1
Gone Wild
 
Join Date: Jul 2016
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Default Make my own battery cables??

I'm more of a person that if I can do it myself and learn in the process I would rather than just buying.

So I'm looking into making my own battery cables out of welding wire...and have a couple questions

1) is 2ga the same as 2/00?
2) where is a good place to source ends? And what's the best material for them.
3) what's the biggest gauge that will still fit through the OBC?

Any advice for things to look out for is welcome!!


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Unread 09-12-2016, 06:29 AM   #2
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Default Re: Make my own battery cables??

I'm in the process of making new cables for my DS. I purchase 2 AWG welding wire at a local welding supply. I'm using tinned copper ring lugs that is common in the marine industry. My cart had 2/0 cables and the lugs were way to big for the 5/16 inch studs on top of my batteries. The 2/0 cables actually were in the way of the battery cell caps so I couldn't check the water levels in the battery without removing the cables. The crimp connection of the wire to the ring lug is vital. I found a 10 ton hydraulic crimp tool on Amazon that so far is working well. I will seal all crimp connections with heat shrink tubing. I was able to slip the 2 AWG welding cable thru the OBC with a light coat of Vaseline.
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Unread 09-12-2016, 06:36 AM   #3
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Default Re: Make my own battery cables??

2/0 is larger than 2awg by about 3 steps. I have fit 4awg through he OBC easily but as was mentioned 2awg will fit with some working at it. You will defiantly need to crimp the terminal on afterward though.

Amazon has some cheap crimpers for these size rings, there is some hammer & anvil type thing for under $25, but there are better suited tools for a bit more.

Terminals I would get from mouser, they don't seem to gouge too much on shipping costs for small quantities to residential addresses. I would get tube-type terminals.

Other than that all you need is a utility knife to strip the ends and something to cut the lengths.
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Unread 09-12-2016, 06:38 AM   #4
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Default Re: Make my own battery cables??

Quote:
Originally Posted by jbsmith05 View Post
1) is 2ga the same as 2/00?
2) where is a good place to source ends? And what's the best material for them.
3) what's the biggest gauge that will still fit through the OBC?
1) No 2 gauge OD is .26 minus insulation whereas 2/00, 2/0 or 00 is .37 minus insulation.... While you can use 2/0 if you want 2 gauge is big enough for a 700 amp cart...
2) Local or Online? Solid Copper is 1st choice, Tinned Copper is 2nd choice...
3) Usually 4 gauge but 2 gauge might fit if it has thin insulation...

Be sure to seal the ends with adhesive lined heat shrink tubing to keep the battery acid vapors from creeping into your wire at the solder joint...
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Unread 09-12-2016, 07:26 AM   #5
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Default Re: Make my own battery cables??

All good info...many thanks!
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Unread 09-12-2016, 01:08 PM   #6
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Default Re: Make my own battery cables??

Does anyone have a source for good quality adhesive heat shrink tube for 2 ga cable?
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Unread 09-12-2016, 01:20 PM   #7
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Default Re: Make my own battery cables??

you can order the shrink tube off Grainger Northern
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Unread 09-12-2016, 09:06 PM   #8
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Default Re: Make my own battery cables??

genuinedealz.com is a great source as well.
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Unread 09-13-2016, 12:22 AM   #9
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Default Re: Make my own battery cables??

http://www.delcity.net/

I ordered some stuff from these guys when I made my own cables..the solder slugs, and connectors came from them. I already had the cable and heat shrink..
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Unread 09-13-2016, 07:29 AM   #10
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Default Re: Make my own battery cables??

By the time I buy the proper crimping device, cable ends, welding cable, bolt for OBC, etc. How much do I save? I see the price of a full set up from a sponsor like Scotty B and I get sticker shock. But I will have a learning curve. Not afraid of doing this. But want to know it will be worth it. I have four carts and would do this for threee of them.
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