battery cables
#1
12-20-2003, 08:49 PM
Join Date: Jul 2003
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#2
12-21-2003, 02:12 AM
the cheapest and possibly the best way to get super high quality battery cables is to make them yourself.
I've done this several times when the stockers are dead.
buy 1 or 2 ought ("0" or "00") welding cable, new terminals and eyes appropriate for the size of cable you use. Crimp or solder the ends where you determine you need them and install.
you can use a string to measure the length of wire you will need for a stretch. use the old harness as a template or schematic and follow it exactly.
if you use "0" or "00" welding wire, it will be capable of handling any load you put to it, winching, jump starting, etc. Remember, if you use too small a wire it will INCREASE the resistance in the circuit.This will cause additional heating and possibly melt contacts or wires. No harm will come if you use a slightly larger gauge of wire than is needed (no increase in resistance will occur if using a larger gauge wire than needed, this is a common misconception) this is "over-engineering" and its a wonderful thing.
make sure to include all the fusible links and that all contacts are the same size as the stock contacts (wire size will be different). this will ensure adequate contact with high amp draw accessories.
use heat-shrink tubing to seal ALL ends, or use plasti-dip for the same, very important to protect the metal portion of this new wiring harness. Any positive cable conductive material that touches a part of the vehicle will cause a short or fire.
you should clean and maintain the batteries also, as they are the most common cause of wire failure due to acid leak. seal the cleaning job with a spray on battery protectant.
Finally, use old heater hose to pad and protect the cables where ever they run against a warm surface or where they are exposed to friction. use small zip ties to hold them on. Note where the retaining clips are for the old cables and use everyone of them. the new cables will be much more flexible than the old ones and will need a few more retaining clips installed to keep them from flopping around (zip-ties, lots and lots of zip-ties !!). the flexibility is very useful
in running the new cables to where they need to go.
you can also paint the appropriate positive cables bright red to mark their polarity.
under no circumstances should you ever use red for negative, red should always be used for positive in automotive work. someone else might work on your car later and the results could be dangerous !!
I have used black for both, but it is worth the time to do a first class job and paint the pos cable red.
these cables will last the lifetime of the vehicle.
I've done this several times when the stockers are dead.
buy 1 or 2 ought ("0" or "00") welding cable, new terminals and eyes appropriate for the size of cable you use. Crimp or solder the ends where you determine you need them and install.
you can use a string to measure the length of wire you will need for a stretch. use the old harness as a template or schematic and follow it exactly.
if you use "0" or "00" welding wire, it will be capable of handling any load you put to it, winching, jump starting, etc. Remember, if you use too small a wire it will INCREASE the resistance in the circuit.This will cause additional heating and possibly melt contacts or wires. No harm will come if you use a slightly larger gauge of wire than is needed (no increase in resistance will occur if using a larger gauge wire than needed, this is a common misconception) this is "over-engineering" and its a wonderful thing.
make sure to include all the fusible links and that all contacts are the same size as the stock contacts (wire size will be different). this will ensure adequate contact with high amp draw accessories.
use heat-shrink tubing to seal ALL ends, or use plasti-dip for the same, very important to protect the metal portion of this new wiring harness. Any positive cable conductive material that touches a part of the vehicle will cause a short or fire.
you should clean and maintain the batteries also, as they are the most common cause of wire failure due to acid leak. seal the cleaning job with a spray on battery protectant.
Finally, use old heater hose to pad and protect the cables where ever they run against a warm surface or where they are exposed to friction. use small zip ties to hold them on. Note where the retaining clips are for the old cables and use everyone of them. the new cables will be much more flexible than the old ones and will need a few more retaining clips installed to keep them from flopping around (zip-ties, lots and lots of zip-ties !!). the flexibility is very useful
in running the new cables to where they need to go.
you can also paint the appropriate positive cables bright red to mark their polarity.
under no circumstances should you ever use red for negative, red should always be used for positive in automotive work. someone else might work on your car later and the results could be dangerous !!
I have used black for both, but it is worth the time to do a first class job and paint the pos cable red.
these cables will last the lifetime of the vehicle.
#3
12-23-2003, 05:38 PM
Join Date: Jul 2003
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Just got my cables for the powerstroke. Custom made by wholesale batteries inc. www.wholesalebatteries.net. Very profesional job price 65.00 shipped.
Last edited by wormslinger; 12-23-2003 at 05:40 PM.