Try this. (Don't recall the author)
Rog
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Building Your Own Battery Cables<o
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Ok guys, after reviving myself after the parts guy gave me the price for battery cables I decided to do my own, here's what I did.....
This article is based on my 1994 F-350 PSD but could be adapted to just about any truck you want.
Here is a list of my supplies-
9 of 2/0ga red welding cable
7 of 2ga black welding cable
4-2/0ga copper eyelet, 3/8 hole
4-2ga copper eyelet, 3/8 hole (battery end of ground cable and ground to frame)
2-2ga copper eyelet, ½ hole (motor end of ground cable)
2-Mill spec + battery terminals (Borg warner p/n BH315P)
2-Mill spec battery terminals (Borg warner p/n BH315N)
4-2/0ga solder pellets (Borg warner p/n CT474)
4-2ga solder pellets (Borg warner p/n CT471)
2-3/4 double wall adhesive lined heat shrink
Start by cutting all your cables to length, on my truck this is what was required
Pass battery + to drivers battery 50 -- 2/0ga
Drivers battery + to starter 45 2/0ga
Both batteries to engine ground 25 2ga (ea.)
Engine ground to frame 18 2ga
Both battery grounds to body 6 10ga (ea)
1. Strip a ½ off the end of the cable
2. Cut a 2 piece of heat shrink and slide over end of cable about a 1 from the end
3. Place the copper eyelet in a bench vice with the cable end pointed up
4. Drop in solder pellet
5. Use a propane torch to heat the eyelet until the solder melts
6. In one smooth motion push the cable down into the eyelet
7. Slide the heat shrink over the eyelet covering the connection
8. Use the propane torch or a suitable heat gun to shrink the heat shrink
Repeat steps 1-8 for all cable ends
9. Clean the starter connection point and both ground points on the block with emery cloth
10. Remove the side battery cables
11. Remove the + side battery cables
12. Install Mill spec terminals
13. Install your new + cable from the starter to pass battery
14. Install you new + cable from drivers battery to pass battery
15. Install you new cables from both batteries to both sides of block
16. Install your new cable from the pass side engine ground to the frame
17. Install your new cables from batteries to body ground
Rog
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