2g cable replacement

Emmster29 · 03-01-2018, 06:25 PM

Aside from the insulation, is there any electrical reason I wouldn't be able to replace a nice custom 2g motor --> controller cable using a piece of standard "gas and oil resistant" 2g THHN that I can get from a big-box store?

Noonan · 03-01-2018, 06:34 PM

I could be wrong but, I don't think there would be a difference in conductivity but the strands in THHN would be fewer and thicker, thereby making the cable much stiffer and harder to manage.

Lochlin · 03-01-2018, 08:03 PM

I cant provide electrical info but when I did my cart I looked at Home Depot and that wire was far too thick and stiff for a cart. Amazon sells all kinds of welding cable and all the fixins to include crimpers. I went that route rather than trying to find a local source.

yawood · 03-01-2018, 10:44 PM

Sergio would be able to provide more qualified information but the way I understand it, AC current likes to travel near the surface of a wire (called skin effect) whereas DC current travels through the whole wire. There is also different behaviour for AC as the frequency rises.

If all that is true then thin strands V thick strands V solid cable does not make much electrical difference for the carriage of 48V DC but the thinner strands make for a more flexible cable that is easier to handle and is less likely to break over time as vibrations cause it to flex. The more solid cable that will not flex would also put a strain on the battery posts and probably cause damage to the battery as the vibrations cannot be absorbed by the less flexible cable.

If it was carrying AC then the thinner strands have a greater surface area and therefore can carry the AC better. But that's not the case in our carts.

NoleFan4Ever · 03-02-2018, 01:06 AM

Also the jacket (insulating material) is different between Excelene and THHN and there is much much less stranding which makes it a lot stiffer and harder to bend and route.

Emmster29 · 03-02-2018, 10:30 AM

Thanks all, And thanks Lochlin for the tip to look on Amazon. They do have good prices on welding cable and I already have a crimper. Free overnight shipping too, should be done with it tonight.

03-01-2018, 06:25 PM	#1
Emmster29 Not Yet Wild Join Date: Oct 2016 Posts: 32	2g cable replacement Aside from the insulation, is there any electrical reason I wouldn't be able to replace a nice custom 2g motor --> controller cable using a piece of standard "gas and oil resistant" 2g THHN that I can get from a big-box store?
Emmster29 Not Yet Wild Join Date: Oct 2016 Posts: 32

03-01-2018, 06:34 PM	#2
Noonan Gone Wild Join Date: Jul 2017 Location: Cape Coral FL Posts: 243	Re: 2g cable replacement I could be wrong but, I don't think there would be a difference in conductivity but the strands in THHN would be fewer and thicker, thereby making the cable much stiffer and harder to manage.

03-01-2018, 08:03 PM	#3
Lochlin Gone Wild Join Date: May 2011 Location: Pittsburgh Posts: 2,942	Re: 2g cable replacement I cant provide electrical info but when I did my cart I looked at Home Depot and that wire was far too thick and stiff for a cart. Amazon sells all kinds of welding cable and all the fixins to include crimpers. I went that route rather than trying to find a local source.

03-01-2018, 10:44 PM	#4
yawood Gone Wild Join Date: Jan 2017 Location: Queensland Australia Posts: 1,332	Re: 2g cable replacement Sergio would be able to provide more qualified information but the way I understand it, AC current likes to travel near the surface of a wire (called skin effect) whereas DC current travels through the whole wire. There is also different behaviour for AC as the frequency rises. If all that is true then thin strands V thick strands V solid cable does not make much electrical difference for the carriage of 48V DC but the thinner strands make for a more flexible cable that is easier to handle and is less likely to break over time as vibrations cause it to flex. The more solid cable that will not flex would also put a strain on the battery posts and probably cause damage to the battery as the vibrations cannot be absorbed by the less flexible cable. If it was carrying AC then the thinner strands have a greater surface area and therefore can carry the AC better. But that's not the case in our carts.

03-02-2018, 01:06 AM	#5
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: 2g cable replacement Also the jacket (insulating material) is different between Excelene and THHN and there is much much less stranding which makes it a lot stiffer and harder to bend and route.

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03-02-2018, 10:30 AM	#6
Emmster29 Not Yet Wild Join Date: Oct 2016 Posts: 32	Re: 2g cable replacement Thanks all, And thanks Lochlin for the tip to look on Amazon. They do have good prices on welding cable and I already have a crimper. Free overnight shipping too, should be done with it tonight.
Emmster29 Not Yet Wild Join Date: Oct 2016 Posts: 32

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