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Old 04-07-2019, 07:54 PM   #1
ChevyIIragtop
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Default 2 Gauge Wiring Upgrade - DIY???

I just had Bob Boyce update my 2015 RXV and am planning to upgrade my wiring to 2 gauge.
I am planning to do it myself, any gotchas to watch out for?
My plan is to remove the positive and negative to the controller first (leaving them for last) and then make and replace each cable.
I bought fine strand copper cabling and copper connectors.
Attached is the first one I made.
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Old 04-07-2019, 08:00 PM   #2
yurtle
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Only gotcha is use only 100% rosin flux, not anything for plumbing.
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Old 04-07-2019, 08:05 PM   #3
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Use some good adhesive lined shrink tubing for protection also.
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Old 04-07-2019, 08:23 PM   #4
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Quote:
Originally Posted by NCPW View Post
Use some good adhesive lined shrink tubing for protection also.
Yeah. I made my battery cables color coded, but "field" cables were all black.

Don't bother to silver plate the copper terminals. It doesn't survive the harsh environment. Looked purty though.

Don't make the mistake I made. "Made in USA" should be top and center on all cables.
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Old 04-07-2019, 08:40 PM   #5
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Quote:
Originally Posted by yurtle View Post
Only gotcha is use only 100% rosin flux, not anything for plumbing.
I am crimping the connectors or am I missing your point?
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Old 04-07-2019, 08:44 PM   #6
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Quote:
Originally Posted by NCPW View Post
Use some good adhesive lined shrink tubing for protection also.
Thanks as this is a point that came up in my research, I've read that shrink tubing, while adding a nice finished look, actually holds moisture creating a corrosion point.
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Old 04-07-2019, 09:03 PM   #7
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Default Re: 2 Gauge Wiring Upgrade - DIY???

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Originally Posted by ChevyIIragtop View Post
I am crimping the connectors or am I missing your point?
I didn't read "crimping" and didn't click on your pic. Ignore flux.
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Old 04-07-2019, 09:06 PM   #8
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Quote:
Originally Posted by ChevyIIragtop View Post
Thanks as this is a point that came up in my research, I've read that shrink tubing, while adding a nice finished look, actually holds moisture creating a corrosion point.
Not good ones. I looked for a link to what I bought, but couldn't find it. Mine are over eight years old, and corrosion would have shown itself as heat.

It is a valid point (maybe?), but you can simply put them in an air conditioned low humidity room before heat-shrinking them. You want to protect the copper conductors - small wires - from the extremely hostile environment of charging and discharging flooded lead acid (FLA) batteries.
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Old 04-07-2019, 11:40 PM   #9
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Default Re: 2 Gauge Wiring Upgrade - DIY???

Quote:
Originally Posted by ChevyIIragtop View Post
I am crimping the connectors or am I missing your point?
According to Trojan, here is the theory (and testing results) regarding mechanically crimped connections:

"Connectors that are mechanically crimped to the cable’s end will create a high resistance area. At high discharge rates, this resistance can create enough heat to melt the terminal post on the battery and/or melt the adjacent insulation on the cable."

"It is therefore highly recommended that connectors not only be mechanically crimped but also soldered to the cable’s end. A properly crimped and soldered connector will provide a low resistance connection and reduce the amount of heat buildup at the connecting junction."

Find the Trojan battery cable document attached below for more information.

If you anticipate high discharge rates for your cart, you may want to consider both mechanically crimping and soldering your connectors.

I am also a fan of color coded shrink tubing that is adhesive lined ... I favor the 3:1 shrink ratio tubing.
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Old 04-07-2019, 11:57 PM   #10
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Default Re: 2 Gauge Wiring Upgrade - DIY???

I'm not debating the findings of this study, but my non-crimped soldered connections have no visible - IR gun - heat gain. That's with an AXE 4855 and eight T-105s with a wild man on the go pedal.
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