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Unread 11-28-2010, 10:32 AM   #1
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Default Making all new battery cables?

I am wanting to make new 2ga. cables for my 2003 Pathway cart. Before I get started on ordering all the cable and ends, how many feet of cable will I need to do the job? I am lifting the cart now and thinking of send the motor to PQ to have it redone for more torque. I'm wanting to put a 500 amp controller.
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Unread 11-28-2010, 10:42 AM   #2
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Default Re: Making all new battery cables?

Might want to PM Cheapjeep hes got that set up. By the way, dont forget to say HBday. Tomorrow he turns 40.
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Unread 11-28-2010, 10:48 AM   #3
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Default Re: Making all new battery cables?

Quote:
Originally Posted by gcs13 View Post
I am wanting to make new 2ga. cables for my 2003 Pathway cart. Before I get started on ordering all the cable and ends, how many feet of cable will I need to do the job? I am lifting the cart now and thinking of send the motor to PQ to have it redone for more torque. I'm wanting to put a 500 amp controller.
Hey gcs, I've been thinking of upgrading my cables too. Probably going to need about 10-12 feet for my cart('93 DS resistor cart). That includes some extra in case I screw up.

Where are you going to order your cables and ends from?

I've also been thinking of getting one of these cable crimp tools from ebay.
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File Type: jpg crimp2.jpg (26.9 KB, 17 views)
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Unread 11-28-2010, 12:16 PM   #4
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Default Re: Making all new battery cables?

I would check with sponsors first. If they dont have what you are looking for then here's a suggestion:

http://www.evsource.com/tls_lugs.php

http://www.evsource.com/tls_cable.php
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Unread 11-28-2010, 01:16 PM   #5
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Default Re: Making all new battery cables?

Thanks for the info. Easydoesit
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Unread 11-30-2010, 01:58 AM   #6
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Default Re: Making all new battery cables?

Save your money. A pair of pliers and a hammer or mallet works great. Just squeeze the connector on tight by hand, then use hammer to hit jaws of pliers once or twice to crimp. Works like a charm!

I just made all new cables for my 92 DS this way. By the way, it took right at 25' of cable to do all the batteries and wires from F&R and controller to motor.

Good Luck,

RGecy
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Unread 11-30-2010, 03:48 AM   #7
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Default Re: Making all new battery cables?

Quote:
Originally Posted by rgecy View Post
Save your money. A pair of pliers and a hammer or mallet works great. Just squeeze the connector on tight by hand, then use hammer to hit jaws of pliers once or twice to crimp. Works like a charm!

I just made all new cables for my 92 DS this way. By the way, it took right at 25' of cable to do all the batteries and wires from F&R and controller to motor.

Good Luck,

RGecy


I totally disagree with this,----this is no way to crimp the ends on your cables,

Let me ask you how many sets of cables you have made this way, and how long have they been working with out problems??

Powered Crimper is a long awaited answer to the need for an economical, ... The Die force is 1.5 tons, and the cycle time is 2 seconds (average). ... extends the range of crimping capabilities to 2/0 AWG conductors in many applications. ... Release lever for relaxing crimp pressure and opening dies



.
BGW...or... anyone on this forum, ... BGW itself, is/are NOT responsible for your actions in the result of using, or, misusing this information that may cause possible damage to yourself, your property, or someone else!
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Unread 11-30-2010, 07:30 AM   #8
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Default Re: Making all new battery cables?

I'm with rib on this one,
it's a surefire way to get a bad cable end connection,
like, for example...
"... I tapped it with a finger and it was extremely hot! Burned the He!! out of me."

Either solder, or have them soldered,
get a crimper, or have them professonally crimped,
or just buy a set that are already done!

my .02


love the disclaimer rib!
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Unread 11-30-2010, 01:28 PM   #9
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Default Re: Making all new battery cables?

I have to agree with these guys. I was just trying to save a few bucks, but if you dont get them right it could cost you more in the end.

I have bought many cables for boats over the years and even made my own this way. I have never had one fail. And then again, they arent always pulling as much juice as these carts do!

Listen to the experts on this one! Sorry for sounding like such a kook!
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Unread 11-30-2010, 02:18 PM   #10
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Default Re: Making all new battery cables?

Quote:
Originally Posted by rgecy View Post
I have bought many cables for boats over the years and even made my own this way. I have never had one fail. And then again, they arent always pulling as much juice as these carts do!
And THAT is the reason we don't use pliers and a hammer.
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