What's too big for rewiring cart??

Nicksel1

Ok so I have a bunch of excess 2/0 gauge wire and lugs. Like the kind for welding. My question is, most everyone talks about using 2 or 4 gauge. Obviously I have free wire and lugs. Would I be overdoing it? Just wondering if I would burn up anything by running such big wire? It's a stock 36v.

BGW

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JohnnieB

Electrically, the bigger the better.
Mechanically, 2/0 might be a little cumbersome getting into the tighter places.
Other than that, go for it!

As for burning things out, there is that possibility since the resistance of the existing cables may be protecting some marginal components like the solenoid and F/R switch (if it is a series cart), but if they are in that bad of condition, they would also burn out if the new cables were 2ga or 4Ga.

Nicksel1

Thanks for the info. I went ahead and started on the wiring. Yes the 2/0 is a mother to work with lol. But I have the batteries done, next is motor and f/r switch. I have attached a picture. Wonder if ill see any speed gains??

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BumbleBee

I was going to say go for it as well. I picked up some 1 gauge weldingcable and made up my ends for 20 bucks. (paid for the lugs, cable was free) I see you soldiered yours in as well good choice. only thing I did differently was add 3M linerless weather tape to the back of the lug to seal the ends a little better. yours are a lot shorter than mine are I gave some wiggle room but then again this build is older and the batteries don't lay out the same. wish they did. keep us posted on if you see any differences!

Arin

JohnnieB

Speed gains? Maybe. It depends on how bad the old cables were.
How fast a series motor spins is limited by the voltage being applied to it.
If the old cables had excessive resistance, you'll see a modest gain in speed.

Once you eliminate the power losses in the Amp delivery system to the motor, the only way to make is spin faster is to increase the battery pack voltage.

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You might just have them removed while replacing the cables, but be sure to secure those batteries or those stiff cables will loosen the studs on the batteries. They are just hex head bolts embedded in lead and right now, the cables on them is all that is holding the batteries in place.

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Also, You might be able to fond some shrink tubing that will go over the logs and seal the lug to insulation air tight so the acid laden air in the battery compartment does seep into the cable and corridor the copped conductors strands.

Nicksel1

It doesn't feel any faster to me, but I still have to run the big wire to the motor. I'll give ya a before and after. And that's a good point, I need to secure the batteries. And also need to seal the lugs to the wire. The old wires were 6 gauge i think. And WAY too long. Prob 6" too long, not sure if the previous owner had them or they were oem. They were slightly corroded so ill take the GPS with me next time out and see what happens.

yurtle

Remember, the motor is connected to the rear-end, which has to flex from full up to full down as far as the suspension. Don't get too short. Your buggy should be able to let you jack her up, without stretching her cables.