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Unread 10-24-2011, 12:31 AM   #1
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Default HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

after many failures and lots of wd-40 ...i found an easy way...

note i used short length of wire just for these photos

The #2 welding cable i got from "THE PUBLIC ELECTRIC COMPANY" was such a high grade that no way would it pass thru the small hole in the on board computer.

so i stripped off a section of the rubber insulation and passed it thru the hole...i also used tape to prevent the wire from fraying as it passes thru and also some tape to prevent JIGGLING in the hole....

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You now replace the section of insulation you previously removed and wrap with electrical tape ...stretching the rubber insulation to close the gap as you tape.
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NOTE: that BARE #2 wire is very loose in the hole and might cause trouble rubbing back and forth had i not taken up slack with some tape.

And my actual modification was with about two feet of bare wire that i re-insulated and crimpted a wire lug on.

need less to say it's important to use rubberized wire insulation as this type stretches back on the wire easily.
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Unread 10-24-2011, 12:43 AM   #2
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

ForBruce can I ask why you would have to do this or why are you doing this so in the future if I need to I can go back to this thread. Thanks.
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Unread 10-24-2011, 01:15 AM   #3
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

Is that welding cable? What is the strand count? It looks more like a braided or twisted cable?

Curious because the #2g 600 strand premium welders cable we use from Excel with neoprene jacket fits thru the hole with a little wd40?.... jacket intact.

hope this helps
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Unread 10-24-2011, 08:57 AM   #4
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

Quote:
Originally Posted by scottyb View Post
Is that welding cable? What is the strand count? It looks more like a braided or twisted cable?

Curious because the #2g 600 strand premium welders cable we use from Excel with neoprene jacket fits thru the hole with a little wd40?.... jacket intact.

hope this helps
ForBruce, The issue I see that caused your problems is the direction you were trying to pass the cable through. If you would have went from the gray side of the OBC, the hole is smooth and tapered, odds are you would have had no problems at all. I've never had a problem going through the way I mention, I can't imagine trying to go the way, you tried through the hole with the blunt edge, no wonder you had problems. I just ran thick heavy duty 2 gauge welding cable through that exact same OBC with out problems by forcing it through the opposite side that you did, the tapered side. Give it a try..
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Unread 10-24-2011, 09:10 AM   #5
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

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Originally Posted by cheapjeep2 View Post
ForBruce, The issue I see that caused your problems is the direction you were trying to pass the cable through. If you would have went from the gray side of the OBC, the hole is smooth and tapered, odds are you would have had no problems at all. I've never had a problem going through the way I mention, I can't imagine trying to go the way, you tried through the hole with the blunt edge, no wonder you had problems. I just ran thick heavy duty 2 gauge welding cable through that exact same OBC with out problems by forcing it through the opposite side that you did, the tapered side. Give it a try..
Good Catch Cheapjeep.
I didn't see that but it makes perfect sense. Hopefully Bruce can try it from the other side and let us know (what type of cable he is using and) if it fits going thru the hole the other direction as your cable and my cable does.
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Unread 10-24-2011, 10:53 AM   #6
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

I did try first passing try thru the smooth gray side of the hole

i just took the photos that way with a 6" piece for demo only so it could be recognized as an "OBC".

SECONDLY.... i tapered the insulation with a razor first and lots of wd40 and only then attempted to incert....did not go

THIRD...... the wire is EXTREMELY hi quallity welding cable from the "ELECTRIC COMPANY" (no-names). when i soldered the battery lugs i noticed the rubber coating doesn't melt or burn...this is by no means regular #2 wire

SCOTTY..... &..... CHEAPJEEP2...send me your address and i will send you a 6" piece to comment on
please note i don't sell this wire and am not trying to promote it.
I cannot possible count the number of strands and i did not notice
any writing on the cable that would explain this....

maybe next week when i close up at the camp ground i will take a
photo of the end of the wire.....


but to summerize this procedure would even work with #1 wire or "1/0 as i needed to tape up the area thru the hold as it had lots of play...once the insulation is removed

you would be supprised how EASY it is to replace the previously removed insulation........this wire is phenomenal..about the best i have gotten my paws on
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Unread 10-24-2011, 11:07 AM   #7
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

Bruce you are reinventing the wheel.
600 strand high quality welding cable fits through the hole intact This is enough for any build especially at higher (4 voltage.
P.S.
I didn't count the strands the manufacture provides specs.
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Unread 10-24-2011, 11:16 AM   #8
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

scotty before you throw stones at me ....maybe you should examine the wire.

I have been working with electricty for 50 years....
both in my job and building radio transmitters as a hobby

call me if you like 917-685-8902

i am offering you a sample at no cost to you or cheapjeep2 just to set the story streight

but please no cheap shots until you know the facts
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Unread 10-24-2011, 11:19 AM   #9
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

Quote:
Originally Posted by ForBruce View Post
I did try first passing try thru the smooth gray side of the hole

i just took the photos that way with a 6" piece for demo only so it could be recognized as an "OBC".

SECONDLY.... i tapered the insulation with a razor first and lots of wd40 and only then attempted to incert....did not go

THIRD...... the wire is EXTREMELY hi quallity welding cable from the "ELECTRIC COMPANY" (no-names). when i soldered the battery lugs i noticed the rubber coating doesn't melt or burn...this is by no means regular #2 wire

SCOTTY..... &..... CHEAPJEEP2...send me your address and i will send you a 6" piece to comment on
please note i don't sell this wire and am not trying to promote it.
I cannot possible count the number of strands and i did not notice
any writing on the cable that would explain this....

maybe next week when i close up at the camp ground i will take a
photo of the end of the wire.....


but to summerize this procedure would even work with #1 wire or "1/0 as i needed to tape up the area thru the hold as it had lots of play...once the insulation is removed

you would be supprised how EASY it is to replace the previously removed insulation........this wire is phenomenal..about the best i have gotten my paws on
NO worries, man, just trying to help you an anyone else that might see this thread that may not have tried to route two gauge, sounds like some bad *** cable you got there.
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Unread 10-24-2011, 11:23 AM   #10
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Default Re: HOW TO INCERT #2 wire thru the ON BOARD COMPUTER

@ForBruce . . . your method works for you and your cable that you procured from the ELECTRIC COMPANY . . . and ScottyB's method works for the cable he uses . . . in my opinion, ScottyB's product and methodology is more simple for the average end user . . .
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