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04-07-2019, 07:54 PM | #1 |
Not Yet Wild
Join Date: Feb 2019
Location: Arizona
Posts: 31
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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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04-07-2019, 08:00 PM | #2 |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: 2 Gauge Wiring Upgrade - DIY???
Only gotcha is use only 100% rosin flux, not anything for plumbing.
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04-07-2019, 08:05 PM | #3 |
Just Gone
Join Date: Sep 2015
Location: North Carolina
Posts: 3,549
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Re: 2 Gauge Wiring Upgrade - DIY???
Use some good adhesive lined shrink tubing for protection also.
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04-07-2019, 08:23 PM | #4 |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: 2 Gauge Wiring Upgrade - DIY???
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. |
04-07-2019, 08:40 PM | #5 |
Not Yet Wild
Join Date: Feb 2019
Location: Arizona
Posts: 31
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Re: 2 Gauge Wiring Upgrade - DIY???
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04-07-2019, 08:44 PM | #6 |
Not Yet Wild
Join Date: Feb 2019
Location: Arizona
Posts: 31
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Re: 2 Gauge Wiring Upgrade - DIY???
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04-07-2019, 09:03 PM | #7 |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: 2 Gauge Wiring Upgrade - DIY???
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04-07-2019, 09:06 PM | #8 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: 2 Gauge Wiring Upgrade - DIY???
Quote:
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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04-07-2019, 11:40 PM | #9 |
Gone Wild
Join Date: Nov 2016
Location: near Calgary, AB, Canada
Posts: 1,516
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Re: 2 Gauge Wiring Upgrade - DIY???
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. |
04-07-2019, 11:57 PM | #10 |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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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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