battery wire gage sizing

[KasDel]

OK guys, a little help here. First I have a 2009 EXGO TXT PDS 36 volt cart. Seems to be all stock. How do you determine wire gage size on the battery pack wiring? It has what appears to be 6g but there is NO markings on the wires. The wires are in good shape but the Batteries are in the toaster and I
was planning on replacing the batteries then changing the wiring to 4g from ScottyB's site (which I may do no matter what). But IF they are 4g now and in good shape so much the better. How to tell according, to web sites I have been pursing, seems to depend on the actual wiring bundle diameter. Getting to that would mean stripping insulation to get to the bare wire bundle. I really don't want to do that unless it is the only way of gaging the size accurately. Can it be determined measuring OVER the insulation? I checks .350 inch in diameter now.

[Sir Nuke]

Not really....as it would depend on the thickness, which obviously change your measurements.

Here is a chart for gauge size, but this is the measurement of the conductor.

wire gauge chart.gif

[KasDel]

Yeah, like I thought.

[KasDel]

By the way, seeing how I haven't figured out the gage size for my present wires yet. Would there be an advantage to switching to 4g for the wiring over 6g. I am running only stock.

[Sir Nuke]

Originally Posted by KasDel

By the way, seeing how I haven't figured out the gage size for my present wires yet. Would there be an advantage to switching to 4g for the wiring over 6g. I am running only stock.

IF you are going to remain stock.....and if you need or replace the cables for any reason....I personally would go ahead and get the larger size. My reasoning is that you never can tell when the MOD BUG will bite you, and the 4 ga. cable set would be good for up to a 400 amp controller.

[Lochlin]

For that matter, Sir Nuke, if you are going to go 4g would it make sense to just go 2g? It's only going to be a few bucks more and that way you are prepared for anything that the Mod Bug will throw your way?

[teecro]

Originally Posted by Lochlin

For that matter, Sir Nuke, if you are going to go 4g would it make sense to just go 2g? It's only going to be a few bucks more and that way you are prepared for anything that the Mod Bug will throw your way?

Generally nothing wrong with overkill namely in the case of battery/motor wiring except there is nothing to be gained by going bigger than 2 gauge unless the wire is free and/or you're building a monster...

[teecro]

Originally Posted by KasDel

By the way, seeing how I haven't figured out the gage size for my present wires yet. Would there be an advantage to switching to 4g for the wiring over 6g. I am running only stock.

Not written in stone by any means but in looking at overall diameter of several types of wire: 6 gauge .31 to .33 & 4 gauge .34 to .38 so while I would tend to think that your .35 is 4 gauge it is much too close to take a blind man's guess...

[scottyb]

2 problems with measuring cable OD

1. jacket thickness varies and effects results.
2. as cables age they corrode internally and expand.

I believe the OEM 6g in this cart were green or blue in color.

[mutant]

overkill is good.