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Unread 06-28-2011, 06:21 PM   #1
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Default Upgrading Cables to 4 gauge

How does one change the cable that runs through the OBC. The space connector is too large to pass through and the diameter of the 4ga. is larger than the original 6ga. How have others done this?
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Unread 06-28-2011, 06:25 PM   #2
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Default Re: Upgrading Cables to 4 gauge

They have left the 6g cable running through the obc and simply put a second 4g on the same terminals at the battery and controller. So there are 2 cables, with one running through the OBC...
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Unread 06-28-2011, 08:04 PM   #3
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Default Re: Upgrading Cables to 4 gauge

You must mean to leave the 4ga. in place thru the OBC and run a 6ga. in parallel. I believe the OBC is reading the amperage running thru the hole in the OBC and a parasllel cable would reduce the amount of amperage flowing on the 4ga. cable thus giving the OBC a reduced reading and false operation.
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Unread 06-28-2011, 09:06 PM   #4
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Default Re: Upgrading Cables to 4 gauge

a 4 gage cable will fit, just leave the end off and when your ready crimp an end on....or some guys run a peice of threaded rod thur and connect cables to each end......it works.................................
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Unread 06-28-2011, 09:09 PM   #5
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Default Re: Upgrading Cables to 4 gauge

Quote:
Originally Posted by donhow View Post
You must mean to leave the 4ga. in place thru the OBC and run a 6ga. in parallel. I believe the OBC is reading the amperage running thru the hole in the OBC and a parasllel cable would reduce the amount of amperage flowing on the 4ga. cable thus giving the OBC a reduced reading and false operation.
Donhow
correct. i personally don't care for this solution.

are your 4awg cables pre-crimped? i used a narrow lug and had no problems threading it through the hole. depending on the type of lug you have, you may be able to grind off some of the width on a bench grinder, with a file, etc.

heres a before and after example. this one was ground down mostly for length, not width though...
-sj
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Unread 06-29-2011, 08:14 AM   #6
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Default Re: Upgrading Cables to 4 gauge

Quote:
Originally Posted by shadowman View Post
a 4 gage cable will fit, just leave the end off and when your ready crimp an end on....or some guys run a peice of threaded rod thur and connect cables to each end......it works.................................

EXCELLENT POINT ABOVE

My 4 gauge cable fit with a little extra work back and forth... without the connector attached. Using a rod through the hole with threads on both ends would be another way to do this without changing your pre-made cables as well.
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Unread 06-30-2011, 11:00 PM   #7
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Default Re: Upgrading Cables to 4 gauge

Thanks for all the responses. I'll grind down the connector to fit through the hole in the OBC.Washers should compensate for the loss of meat on the connector. However, if that fails I'll crimp on a connector after running the bare cable through the OBC.
Thanks again,
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Unread 07-01-2011, 10:03 AM   #8
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Default Re: Upgrading Cables to 4 gauge

Take a 3" length of 5/16 threaded stainless steel. Wrap a 1/2" thick piece of insulator tape in the center. Stack yourself 2 x 1 1/2" neoprene 5/16 washers, 2 x 1" 5/16 plastic washers. One on each side of the tape gap. Then stainless washer and nut on either side to snug the shaft up in the hole. Then the stainless washers and nuts to make battery posts on either side after the first set of washers and nuts. 3" works depending on the thickness of your washers.

Be careful not to overtighten the nuts after placing stack through the hole and you obviously have to hold the first set of nuts with a wrench when tightening the final nuts. Now you essentially have battery posts on either side of the OBC and you can do whatever thickness of cable you want. It looks like CC made it that way. I used 4 gage I had custom made by a guy on eBay. They were beautiful. You can have them color coded to the stock cables. Coat everything in dielectric grease.

I'm on the road or I would send a pic. Hope this helps.
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Unread 07-01-2011, 02:12 PM   #9
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Default Re: Upgrading Cables to 4 gauge

96ironman: Thanks for the info. You have a good solution.
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