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Old 02-10-2010, 07:11 AM   #1
Hillbilly Deluxe
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Default 4g vs. 2g revisited

I checked with a local welding shop after asking the question about upgrading my wire size on my 87 cc 36 volt. I can get a roll of 4g (25ft) for about $40 and 2g for about $60. This seems to be high quality fine strand wire. The guy was very nice explaining that if I gave him the lengths he would crimp all of the lugs on for me... better than I could. The question is, is it worth it (extra $20 or so) to go with 2g? Any downsides to larger wire etc? I am assuming 25 ft. would be enough for all of my runs.
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Old 02-10-2010, 09:17 AM   #2
K-DAWG
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Default Re: 4g vs. 2g revisited

If you ever upgrade to a 500 amp controller or larger you will need 2 ga.
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Old 02-10-2010, 09:30 AM   #3
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Default Re: 4g vs. 2g revisited

For $20 why not? Also, you'll want to solder the connections not just crimp them.
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Old 02-10-2010, 09:52 AM   #4
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Default Re: 4g vs. 2g revisited

4g will suffice for all but the most extreme builds Like Kdawg's wheelie machine. I have built a few 450 - 650 amp controller 48v converted CCs with 4g wire and Soldered lugs. Never a problem or complaint. The wires will last as long as the batteries so they are a renewable part. 4g is enough for all but the carts which can draw more than 400amps with big motors etc. Hope this helps.
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Old 02-10-2010, 07:46 PM   #5
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Default Re: 4g vs. 2g revisited

I was told to use "silver solder" is this a must?
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Old 02-10-2010, 11:40 PM   #6
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Default Re: 4g vs. 2g revisited

I guess not? ..... It just makes the best connection.
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Old 02-10-2010, 11:44 PM   #7
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Default Re: 4g vs. 2g revisited

4 gauge is sufficient for your resistor cart. A good cable crimper is also good. Solder isn't as much a need as a proper crimp - IMO...

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Old 02-11-2010, 09:20 AM   #8
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Default Re: 4g vs. 2g revisited

As I understand soldering with silver solder requires the heat of a torch on something this thick? Would you recommend removing some of the outer cable coating and replacing it with heat shrink? Also any advice on what % silver content and were to buy? (radio shack, welding shop etc.)
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Old 02-11-2010, 09:30 AM   #9
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Default Re: 4g vs. 2g revisited

Silver solder can be found a Lowes/HD or any plumbing supply store. You need a torch and flux. if you are unfamiliar with solder you may want to use the crimp method? Some like the shrink wrap ... I use liquid rubber for an airtight seal. There is no right or wrong way to do it. Just figure out what will work best for you to get the most solid air tight seal and keep them clean and the nuts tights for a long useful life.
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Old 02-11-2010, 09:38 AM   #10
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Default Re: 4g vs. 2g revisited

So it is either crimp or solder... but not both...
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