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Unread 06-17-2017, 10:54 PM   #1
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Default Upgrading to #4 AWG on 06 DS IQ 48v

Getting ready to start to get going onto the next phase of making my cart into a good all around cart that will fit my needs.

Which for me means the drivetrain. I'll do it in small steps since electrical isn't my thing and I want to keep the changes small in case I need to debug. I'm not doing a total rebuild, just an upgrade.

First easy step will be switching over to #4 from #6 AWG wires. From what I can see all I need do is convert 8 wires over. I highlighted them on the attachment.

What is throwing me is when you buy wires off the internet you either get less then 8, or a whole stack of them. I'm guessing that all #6 wires are carrying the real load and should be the ones replaced for the future coming of a larger controller/solenoid.

Am I missing something here? Is 8 really all there is even though they sell less, or a lot more, but never just 8 to cover the #6 AWG that is OEM?
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Unread 06-17-2017, 11:30 PM   #2
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

you are correct , 8 cables need to be upgraded
the one going through the OBC needs a stud



scottyb makes cab;es to fit your cart with the OBC kit

http://www.cartsunlimited.net/battery-cables.html
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Unread 06-17-2017, 11:44 PM   #3
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

There is an alternative to the stud, and that is a screw on ring terminal. This can be installed on the new 4 Gauge cable once you have passed it through the OBC.

http://www.ebay.com/itm/Xscorpion-4-...cAAOSwlY1ZFHjy

Attached is a link of one example, I am sure that Site sponsors can provide them to you as well.

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Unread 06-18-2017, 12:02 AM   #4
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

no
there is no way a 4g cable fits through an OBC
you can not drill out the OBC
you can get a dpi charger to eliminate the OBC
or build a stud your self

no they are soldered lugs on the cables
you do not want a screw on connector
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Unread 06-18-2017, 12:12 AM   #5
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

Quote:
Originally Posted by crash test dummy View Post
no
there is no way a 4g cable fits through an OBC
you can not drill out the OBC
you can get a dpi charger to eliminate the OBC
or build a stud your self
no they are soldered lugs on the cables
you do not want a screw on connector
CTD, 2 AWG will actually fit through the OBC buddy (4 AWG is really easy). I have #2 on my '07 IQ and my dad's '96 Series cart. Put a little silicone on it and it pulled right through. And this is high quality cable. 2 awg/gauge 600v Excelene Welding cable.
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Unread 06-18-2017, 12:15 AM   #6
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

Quote:
Originally Posted by Cruise Master View Post
-snip-
Am I missing something here? Is 8 really all there is even though they sell less, or a lot more, but never just 8 to cover the #6 AWG that is OEM?
CM where are you located in the South? Are you here in Florida? If so, come by and we will make you a set exactly as you need.
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Unread 06-18-2017, 12:15 AM   #7
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

wow ..... i stand corrected .... i always was told it won't fit ... sooo when i did a 4g upgrade i built a stud kit



i like your - snip -
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Unread 06-18-2017, 12:18 AM   #8
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

Quote:
Originally Posted by crash test dummy View Post
-snip-
you do not want a screw on connector
Bump! Listen to CTD, This can get you in a lot of trouble with high load usage and/or effect longevity....
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Unread 06-18-2017, 12:22 AM   #9
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

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Originally Posted by crash test dummy View Post
wow ..... i stand corrected .... i always was told it won't fit ... sooo when i did a 4g upgrade i built a stud kit



i like your - snip -
Yes Pal, you could have used #2, but if you had the lugs already on you were forced to use the stud. I make all mine and my friends so I have all the tools here and I apply the lug after I go thru the OBC. What I hate is the inherent resistance loss you get going across the stud - it reduces the gain of the larger cable.

Yes, I "-snip-" so as to only catch the important part and place emphasis there.
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Unread 06-18-2017, 07:08 AM   #10
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Default Re: Upgrading to #4 AWG on 06 DS IQ 48v

Quote:
Originally Posted by NoleFan4Ever View Post
CM where are you located in the South? Are you here in Florida? If so, come by and we will make you a set exactly as you need.
WOW, that's really nice of you! We travel around, but mostly we winter up and down the Texas coast ending up on SPI before heading north again. The winter after this one we may head in your direction, something different.

I figure I would trailer the cart to a local shop then pull the #4 thru the OBC, and have them crimp on the ends for me. Live in a small town where they do stuff like that still. Or I may buy all the tools and try it myself. Haven't got to that part yet. Still need to do some homework.

Thanks for the kind offer again.
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