Electrical Upgrade... Welding Cable?
Posting Guru
Joined: May 2014
Posts: 1,072
Likes: 0
From: Dustbowl, NV
We use both styles at work- the copper crimpable terminals only when there is space limitations. I've seen them crack at the narrow point of the terminal. Never seen an issue with the military style... they're bomb-proof! Them with a good quality copper lug, and it should be good for the life of the vehicle.
PS Be aware if ya don't know; there are positive and negative terminals, they are sized slightly different but can be forced into use on either battery post... bad, bad, bad!
PS Be aware if ya don't know; there are positive and negative terminals, they are sized slightly different but can be forced into use on either battery post... bad, bad, bad!
Last edited by holeshotwalt; Jun 22, 2015 at 02:37 PM. Reason: add ps
Postmaster
Joined: Dec 2010
Posts: 2,951
Likes: 4
From: Gary,Indiana
We use both styles at work- the copper crimpable terminals only when there is space limitations. I've seen them crack at the narrow point of the terminal. Never seen an issue with the military style... they're bomb-proof! Them with a good quality copper lug, and it should be good for the life of the vehicle.
PS Be aware if ya don't know; there are positive and negative terminals, they are sized slightly different but can be forced into use on either battery post... bad, bad, bad!
PS Be aware if ya don't know; there are positive and negative terminals, they are sized slightly different but can be forced into use on either battery post... bad, bad, bad!
Now I just need to figure out what size wire so I can buy the lugs. As I have been checking around I have not seen an answer to what size wire the battery cables are. So went to measure the wires and I came up with ground wires were .50 and .20 with the insulation on and the positive lead on the drivers side was .40 with the insulation on and on the passenger side positive it was .62 and .26 with the insulation on.
Which I come to find out does me NO good because you need to measure WITHOUT the the insulation on !!
Per this wire calculator: Wire Gauge & Diameter Calculator ? 66pacific.com
So I guess I'll strip off the insulation near the battery terminals and start all over.
I'll report back when I do find out what size the wires are.Also I found this a interesting read: http://standards.sae.org/uscar21-3/
Last edited by BadDogKuzz; Jun 22, 2015 at 06:29 PM. Reason: Added Stuff
Hotshot
Joined: Jan 2002
Posts: 17,988
Likes: 207
From: La La Land
I'm not a fan of using zinc anywhere around acid. It's way too "active" a metal, and is eaten relatively quickly by battery acid and its fumes.
They made them out of lead, for DECADES, for a reason!
The positive terminal on my driver's side is already copper from the factory, and if kept clean should last a lifetime.
Pop
They made them out of lead, for DECADES, for a reason!
The positive terminal on my driver's side is already copper from the factory, and if kept clean should last a lifetime.
Pop
Senior User
Joined: Jun 2015
Posts: 284
Likes: 0
What Gauge??
Yea I knew that about the positive and negative being a different size. I learned that one the hard way many years back. LOL Thanks for your input and after what you said about the terminal cracking on the copper crimp ones I think I will go with the military style.
Now I just need to figure out what size wire so I can buy the lugs. As I have been checking around I have not seen an answer to what size wire the battery cables are. So went to measure the wires and I came up with ground wires were .50 and .20 with the insulation on and the positive lead on the drivers side was .40 with the insulation on and on the passenger side positive it was .62 and .26 with the insulation on.
Which I come to find out does me NO good because you need to measure WITHOUT the the insulation on !!
Per this wire calculator: Wire Gauge & Diameter Calculator ? 66pacific.com
So I guess I'll strip off the insulation near the battery terminals and start all over. I'll report back when I do find out what size the wires are.
Also I found this a interesting read: USCAR213: Performance Specification for Cable-To-Terminal Electrical Crimps - SAE International
Now I just need to figure out what size wire so I can buy the lugs. As I have been checking around I have not seen an answer to what size wire the battery cables are. So went to measure the wires and I came up with ground wires were .50 and .20 with the insulation on and the positive lead on the drivers side was .40 with the insulation on and on the passenger side positive it was .62 and .26 with the insulation on.
Which I come to find out does me NO good because you need to measure WITHOUT the the insulation on !!
Per this wire calculator: Wire Gauge & Diameter Calculator ? 66pacific.com
So I guess I'll strip off the insulation near the battery terminals and start all over.
I'll report back when I do find out what size the wires are.Also I found this a interesting read: USCAR213: Performance Specification for Cable-To-Terminal Electrical Crimps - SAE International
Have you determined the gauge size of the factory wire? I was going to replace just a section of the positive cable by using the Remy preloaded Butt Splice terminal and then replace the section that connects the 2 batteries with the Remy solder connectors.
Fleet Mechanic
Joined: Mar 2009
Posts: 1,856
Likes: 52
From: Sacramento Delta, CA
Gatordog: You probably already have thought about this, but Raychem and others make an adhesive shrink tube of large diameter which you can slide on before you make the butt connections and then slide over the butt splice and shrink. I did this on the house side battery connections on my van and that big ashesive-lined shrink tube makes an insulated, abrasion resistant and I think airtight connection. (Home Depot also sells shrink tube like this in their big gauge wire splice repair section of the electrical aisle.)
Postmaster
Joined: Dec 2010
Posts: 2,951
Likes: 4
From: Gary,Indiana
I'm not a fan of using zinc anywhere around acid. It's way too "active" a metal, and is eaten relatively quickly by battery acid and its fumes.
They made them out of lead, for DECADES, for a reason!
The positive terminal on my driver's side is already copper from the factory, and if kept clean should last a lifetime.
Pop
They made them out of lead, for DECADES, for a reason!
The positive terminal on my driver's side is already copper from the factory, and if kept clean should last a lifetime.
Pop
NOCO TZ625 | Fisheries Supply
So when I get around to it I'm going to give them a try and see first hand for myself.
Gatordog: You probably already have thought about this, but Raychem and others make an adhesive shrink tube of large diameter which you can slide on before you make the butt connections and then slide over the butt splice and shrink. I did this on the house side battery connections on my van and that big ashesive-lined shrink tube makes an insulated, abrasion resistant and I think airtight connection. (Home Depot also sells shrink tube like this in their big gauge wire splice repair section of the electrical aisle.)
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