Battery (DIY) Internals DIY wire gauge used?

davros · 11-20-2024, 02:05 PM

Ive been using some EV grade (welding cable-ish) 1/0 cables for post to shunt etc but proving to be a struggle on some of the bends.
What gauge did you gents use in your build?

Capt. Lenny · 11-20-2024, 02:58 PM

I used #2 gauge welding cable for everything because that's what I had previously. The 2 wires on the JK BMS I used has 2-#7 wires going in and coming out of it and they don't even fill a #2 butt connector very well. I added a couple pieces of #10 in the butt connector to fill the extra space up so I got a tight connection. I personally think #1 gauge is overkill and not really necessary unless you plan on pulling a hell of a lot of current. I have my shunt connected directly to the pass thru connector and the negative #2 coming from the BMS. It worked out very well. Another option is to use a piece of copper busbar.

Timothy L · 11-20-2024, 03:07 PM

I normally use 4g welding cable. For the 72v cart I built myself I used 2g for the main positive. I also used 2g to replace cables on a cart I repaired for someone that was having melting issues with the original light duty cables after lifting it.

jasonojordan · 11-20-2024, 03:20 PM

I used 4ga on my DIY build as well. It matched up well with the leads coming out of the JK bms.

Capt. Lenny · 11-20-2024, 05:15 PM

Quote:

Originally Posted by jasonojordan

I used 4ga on my DIY build as well. It matched up well with the leads coming out of the JK bms.

I knew they would match up better to #4 gauge but #2 gauge was what I had. So I found a work around.

11-20-2024, 03:07 PM	#3
Timothy L Getting Wild Join Date: Nov 2018 Posts: 143	Battery (DIY) Internals DIY wire gauge used? I normally use 4g welding cable. For the 72v cart I built myself I used 2g for the main positive. I also used 2g to replace cables on a cart I repaired for someone that was having melting issues with the original light duty cables after lifting it.
Timothy L Getting Wild Join Date: Nov 2018 Posts: 143

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11-20-2024, 02:05 PM	#1
davros Gone Wild Join Date: Mar 2024 Location: ontario/florida Posts: 278	Battery (DIY) Internals DIY wire gauge used? Ive been using some EV grade (welding cable-ish) 1/0 cables for post to shunt etc but proving to be a struggle on some of the bends. What gauge did you gents use in your build?

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11-20-2024, 02:58 PM	#2
Capt. Lenny Born to be Wild Join Date: Feb 2019 Location: Palm Harbor Florida Posts: 3,953	Re: Battery (DIY) Internals DIY wire gauge used? I used #2 gauge welding cable for everything because that's what I had previously. The 2 wires on the JK BMS I used has 2-#7 wires going in and coming out of it and they don't even fill a #2 butt connector very well. I added a couple pieces of #10 in the butt connector to fill the extra space up so I got a tight connection. I personally think #1 gauge is overkill and not really necessary unless you plan on pulling a hell of a lot of current. I have my shunt connected directly to the pass thru connector and the negative #2 coming from the BMS. It worked out very well. Another option is to use a piece of copper busbar.

11-20-2024, 03:20 PM	#4
jasonojordan Gone Wild Join Date: Sep 2022 Location: Minnesota Posts: 1,836	Re: Battery (DIY) Internals DIY wire gauge used? I used 4ga on my DIY build as well. It matched up well with the leads coming out of the JK bms.