Notices
1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

Battery cable upgrade

Thread Tools
 
Search this Thread
 
Old Apr 3, 2016 | 08:26 PM
  #1  
kellen302's Avatar
kellen302
Thread Starter
|
Senior User
Joined: Aug 2014
Posts: 120
Likes: 0
Battery cable upgrade

So my battery cables are 23 years old and the insulation has a few cracks on some of the sharp bends. I would also like to add power and ground terminal bars on the fender for wiring auxiliary items like my CB, and some lights, maybe a small inverter or sub/amp in the future. I would also like to set this harness up to accept a 3G swap. I figure I can get it made by a local welding shop or NAPA if I have accurate drawings to work off of. I figure 2ga. is probably the best compromise between cost and capacity but that can change if needed.

Below is a diagram from custombatterycables.com that they show for an OBS F150 with V8. How accurate is this diagram? Also, any recommendations on how to do the battery post terminals to allow for an extra heavy gauge lead for the bus bar on both positive and ground sides?
1993 F150, 4.9L/M5OD 4x4




THANKS!
 
Reply
Old Apr 5, 2016 | 03:00 PM
  #2  
kellen302's Avatar
kellen302
Thread Starter
|
Senior User
Joined: Aug 2014
Posts: 120
Likes: 0
Anybody?
I'm really just looking to see if these lengths seem right for a 4.9, and any recommendations on how to set up the battery posts, I saw some "Military Style" Terminals that have a long bolt to put multiple heavy ring terminals on which would be nice because it could be easily expanded.
 
Reply
Old Apr 5, 2016 | 03:44 PM
  #3  
Mudsport96's Avatar
Mudsport96
Logistics Pro
15 Year Member
Liked
Loved
Community Favorite
Joined: Aug 2010
Posts: 3,718
Likes: 586
From: Chillicothe
I'm not sure on factory lengths, I typically use welding cable when I make new starter cables. And use Burndy crimp ends for eyelets.
 
Reply
Old Apr 5, 2016 | 04:19 PM
  #4  
timbersteel's Avatar
timbersteel
Logistics Pro
Joined: Mar 2005
Posts: 4,698
Likes: 47
From: Mexico, Missouri
48" 2/0

I made an entire new cable at a Big Rig shop with soldered ends.

Next I took the spare cable from the truck and added it to the other truck.

I will post pics a little later to give you an idea.
 
Reply
Old Apr 5, 2016 | 05:18 PM
  #5  
timbersteel's Avatar
timbersteel
Logistics Pro
Joined: Mar 2005
Posts: 4,698
Likes: 47
From: Mexico, Missouri
Here's a few pics







I have 2/0 running to the starter
4 ga. To the fender-mounted relay
2 ga. To the 3G alternator
 
Reply
Old Apr 5, 2016 | 07:47 PM
  #6  
kellen302's Avatar
kellen302
Thread Starter
|
Senior User
Joined: Aug 2014
Posts: 120
Likes: 0
That looks like exactly what I'm trying for, do you remember the lengths off hand?
You said 48" up above but I think that would only cover one of the cables.

Thanks
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
blueeyedfordguy
1997 - 2003 F150
2
Oct 19, 2013 09:07 AM
busflyer
Electrical Systems/Wiring
7
Aug 16, 2011 01:43 AM
884x4broncoII
1994.5 - 1997 7.3L Power Stroke Diesel
1
Dec 24, 2009 03:43 PM
95 Snake
1978 - 1996 Big Bronco
2
Oct 26, 2005 03:06 PM




All times are GMT -5. The time now is 11:37 AM.

story-0
This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

Slideshow: The VelociRaptor Expedition gains a lift, upgraded suspension, Brembo brakes, and trail-ready equipment while retaining the stock 440-horsepower EcoBoost V6.

By Verdad Gallardo | 2026-06-12 11:01:55


VIEW MORE
story-1
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-2
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-3
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-4
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-5
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-6
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-7
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-8
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-9
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE