Battery cable diameter?
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Lead Driver
Joined: Oct 2003
Posts: 8,476
Likes: 37
From: Madison, WI
Battery cable diameter?
Swapping batteries on the '85 F250, I felt a "snap" when loosening the passenger-side positive terminal. Haven't had occasion to try it yet, but I'm sure it's cracked. I'm trying to figure out what diameter/gauge the bigeffin' wire is going down to the starter. It looks like so PO might have even replaced it with welding wire. I tried measuring it with a caliper, then comparing to the chart here: https://en.wikipedia.org/wiki/American_wire_gauge , but with the insulation, it didn't do me much good. It's about .65" with the insulation. Should I just go ahead and assume it's something huge like 4/0? Or would it be closer to 1/0?
Postmaster
Joined: Feb 2011
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i'm guessing its probably 2/0, but i haven't gotten around to replacing mine so i'm not dead sure.
if you're cable is still in good shape and its just a bad end, any shop that makes custom cables can put a new end on your old cable for you. but of course if your wire has big bare spots and is corroded up like many of ours, then this is the excuse to go with a new wire
if you're cable is still in good shape and its just a bad end, any shop that makes custom cables can put a new end on your old cable for you. but of course if your wire has big bare spots and is corroded up like many of ours, then this is the excuse to go with a new wire
Laughing Gas
Joined: Sep 2012
Posts: 1,100
Likes: 6
From: Georgia
Find out what the max draw of the starter is (cold engine winter time), measure the length and use welding cable in a size that will give you less that 0.5v volt drop. Use quality heavy duty lugs and moisture seal heat shrink tubing. If someone posts what the current draw is and you post the cable length, I can can tell you what size would be ideal.
You can solder them if you want, but I've been making cable for a long time and a quality crimp is all you really need. I've cut open lugs I've crimped on and after over 10 years under the car the wire looks as new as the day I did it.
You can solder them if you want, but I've been making cable for a long time and a quality crimp is all you really need. I've cut open lugs I've crimped on and after over 10 years under the car the wire looks as new as the day I did it.
Lead Driver
Joined: Mar 2006
Posts: 5,111
Likes: 1,546
From: western SD
On these old gals, the cable from the drivers side battery to the passenger side battery was 2/0 gauge. From the passenger side to the starter was 3/0. This was the size from the factory. I beleive the replacement cables are all 2/0 now. So if your cables are still factory, you should have 3/0 going to the starter.
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Lead Driver
Joined: Oct 2003
Posts: 8,476
Likes: 37
From: Madison, WI
^^^^ That's about how they look; starter cable is def. bigger than the crossover. Problem is, all the "flag" terminals (for two cables) are the same size on both sides. I suppose if I get a 3/0 terminal, and put the starter relay wire in the crimp for the crossover (and I think I'll put the GPR wire in there as well, for a more direct run), and fill with solder as needed, I should be good to go. Thanks for the 411.
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