New 2 gauge cables with 3/8 lugs.

[FireEMT978]

Curious? I bought a set of 2 gauge welding cables with 3/8" lugs on all of them.
I am converting to 48 volt.
2 questions:
1) My stock 2000 series TXT has small 5/16" studs on the motor. What should I do to fasten the 3/8" lugs? Washers, etc... to utilize the lug. Or, should I just tighten the large lug to the stud even though it won't seat as it should to utilize the full connection?
2) Anybody have a ideas for mounting an SW202 reversing contactor without a bracket on it?

Thanks much.

[Sir Nuke]

Originally Posted by FireEMT978

Curious? I bought a set of 2 gauge welding cables with 3/8" lugs on all of them.
I am converting to 48 volt.
2 questions:
1) My stock 2000 series TXT has small 5/16" studs on the motor. What should I do to fasten the 3/8" lugs? Washers, etc... to utilize the lug. Or, should I just tighten the large lug to the stud even though it won't seat as it should to utilize the full connection?
2) Anybody have a ideas for mounting an SW202 reversing contactor without a bracket on it?

Thanks much.

you want full contact.....I would use Stainless washers.

[Sergio]

All battery posts are also 5/16.

3/8 lugs are the wrong size for a golf cart and can lead to loose connections due to vibration since the lugs can move.

[FireEMT978]

Originally Posted by Sergio

All battery posts are also 5/16.

3/8 lugs are the wrong size for a golf cart and can lead to loose connections due to vibration since the lugs can move.

This is my concern.
If I "sandwich" between stainless washers, and the nut, is that sufficient?

[meangreenmachine72]

That's what I would do. Just be careful when you tighten them not to damage battery terminal.

[tag50]

I would use external tooth lock washers.


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[Volt_Ampere]

Do NOT put a washer between the lug and the battery terminal. Stainless is not that great a conductor by the way. If you get a bad connection you will melt the battery terminal - expensive. Better to get the right lugs and cables.

[cgtech]

When the washer arrangement starts failing (melted battery terminals, fried motor studs) , just take them all off and have the correct terminals installed.

[scottyb]

Basically they are trying to tell you that the having the correct size lug end is critical to maintaining a good connection. Rarely do I make a set with all the same size lugs, some sets have 3 different size lugs in the set to insure maximum contact at all points.
A poor connection can cause damage to both cable and component. It may be best to contact the seller and ask they change the ends on the majority of the cables which do not need them.
Likely you only need 6 - 3/8ths ends out of the 26 you have

[Volt_Ampere]

As scottyb suggested you are far better off getting the right size lugs installed on your cables! Pay me now or pay me later!