I need to repair the ends of my battery cables. Looking at something like this.
https://www.amazon.com/Military-Spec...XT0H0Y11QVCP9C

I am trying to figure out the wire sizes for the crimp connectors. The drivers side measures (with insulation) about 10.4 and 12.4 mm, is that 3/0 and 4/0?

The biggest wire on the p side pos measures over 16mm, is that a 6/0?

I don't own a crimper for these sizes but I'll get one if I need to. Open for suggestions.

 

Custom Battery Cables F350 cables

 

I always make my own cables.
I use 00 gauge wire, the bigger the better, IMO.
also, I like upgrading to group 31's
overkill in your starting system is never a bad thing.

 

I can buy a whole set of crimpers for that price. just can't imagine that all that copper is bad.

 

Mine was, Doug. Burned up alternator after alternator for a couple of years. All the wiring was corroded and green from the B+ cable coming off the back of the alternator to the entire positive battery harness. A brand new battery harness (all the red cables) is only about $85 from Rockauto. You will spend way more than that on crimpers and custom cable ends. I then replaced my B+ with high current 4 gauge wire. That was a lot trickier, as I had to come up with new splices/connections for my glow plug module and AIH relay.

 

Well Hell, at least I have run out of payments. I did buy pair of batteries yesterday. Everything fits a little tighter.

Mike is not often wrong on these deals so I guess I'll shop up some new cables while I'm living near my garage again.

cheers
doug

 

I bought a whole new positive wire harness, and I bought those mil spec battery terminal top post clamps (and covers) for the negative side. As for the lugs, I opted not to crimp - I bought Fastronix Eyelet Style Battery Terminals.

 

Doug, It is under: electrical>starter cable. Price went up to $96 since I bought mine last year.

 

I don't have one of those fancy hydraulic crimpers either, and I've always wanted one. But if you have a shop press, or even simply a bottle jack and a sturdy fixture, you can improvise crimps with block dies that are much cheaper to find, buy, or make... for an equivalent (if not greater) crimping and conforming force on the connection.

This is how I made a couple of battery cables just recently. I'm not a fan of the wire, but I already had it on hand, salvaged from someone's decommissioned $20K stereo install...

 

I am pretty sure that a good vice will give you enough pressure to make a good crimp using those dies. A little lube on the vice threads will help.

But, if you have to jusify a new hydraulic press, nuthin wrong with that!

Oh, and a little grease inside the lug probably would inhibit corrosion also.

Larry

 

Ha, I wish that press were new. It was a 40 year old craigslist find, and that was 10 years ago. I simply painted it and put new hoses and hardware on it. The ram leaks like a sieve. It was a challenge keeping the hydraulic oil from pouring all over the connections like pancake syrup. Although, that might obviate the need for grease...