Quick question.

When I replace my batteries in the coming week, I'm going to go ahead and replace the entire battery cable set with newer and heavier duty. My question is regarding cost justification.

Choice "A" = purchase a set of HD battery cables made by XPD.
Choice "B" = make my own which would include having to purchase a decent crimping tool which I'll rarely if ever need again. If I go this route, I'll have more options for which lugs to use.

What say you... is the HD kit made by XPD decently priced in comparison to the full (tool included) cost of doing it myself?

 

If you are going for one and done, option A.

If you think you may have a use for the tool in the future and want to take the time (that should be a cost factor as well) to build your own, option B. I selected option B a few years ago because I had an RV solar installation on the calendar. I bought a 16 ton crimper with dies from Amazon and it got a workout. I bought high quality lugs and wire made the cables to the length I wanted based on the route I selected.

Nothing wrong with buying something and installing it if that is easier and less costly when you consider your time and effort.

 

At this price I would just buy the tool. Then the door is wide open for a custom setup.

 

I went for Option A (with a different brand of cables) despite being a confirmed tool nut.

 

I bought from Custom Battery Cables and got the "hard start" option, I'm very happy and was well worth it.


Obviously DIY would be a little bit cheaper but ask yourself the question do you have the time? Or patience? I sure didn't at the time.

 

Do you have a single alt or Duals?

I just bought a 250 amp, powder coated alt. and I need to up grade my cables or run a parallels set. But have not been able to find a Dual alt premade kit.
I may have to go DIY or buy 2 kits.
I was just concerned that the lengths would not be right for the second alt.

 

Was the Custom Battery Cables kit well made? I was looking at ce auto electric supply.com, but they're almost $100 more and they don't use a 3/0 battery to starter wire like Custom Battery Cables does.
At first I was just gonna replace the terminals as 2/4 of mine are cracked. But then I started thinkin that all new cables wouldn't such be a terrible idea. With that being said, the truck did fire right up when it was 6 degrees outside after sitting overnight not plugged in.
And I most definitely do not have the time or patience to make my own kit.

 

Very well made kit, I have no complaints here's a video of my truck (green OBS) starting up with 5 year old batteries and the new cables.
Notice the difference in cranking speed on the white truck (stock wires) vs the green

 

I have the CE Auto Electric Kit and added the alternator wiring kit. It is super high quality and works great.

 

I'll give another nod to custom battery cables. I ran those on my 7.3idi and they are high quality.
If not going DIY, that is what I would do.

 

Back when I owned a boat, I replaced a lot of wire/battery cables connectors etc... salt water has a significant negative impact on most metals, but it taught me a lot. I replaced the starting circuit on the boat three trucks (F250, f350, 2500 Ram) and my tractor. Doing it myself allowed me to do it my way, with cable and connectors that I wanted.

I invested in a hand crimper ( ), not super cheap but really not all that expensive.

For the Boat I used Marine grade (tin plated) copper wire, the tin helps keep the wire from corroding under/inside the insulation. For the land based vehicles, I used copper welding cable. Welding cable is made to a different industry standard, finer strands provide greater flexibility, The insulation is a bit better as it needs to resist oil, abrasion and heat better than battery cables, and it's also rated for a higher Amps.

If you DYI, invest in USA made wiring and connectors, stay away from Copper Clad Aluminum (CCA), basically a flashing of copper over aluminum wire, and don't believe the hype of "oxygen free copper" (OFC); pretty sure it's a made up term, as there are no NEC specs for it.

All my lugs were USA made (FTZ Brand) marine grade (tin plated copper).

Respectfully

Mike

Mike

 

I have no doubt the wire and lugs in some of the prebuilt kits is top notch. Although, if you go the DIY route you are able to select the wire. You are able to select the country of origin, the seller, the strand count, the quality of the copper, the sheath material and the temperature rating. As you most definitely know Pete, there is more to making a wire choice than the gauge. I was able to add fuses, auxiliary equipment and certain lengths in order to take a route with the cable I preferred.

As Mike did, I used high quality wire with a high strand count which made even the 4/0 wire very flexible. The lugs were all robust, appropriately sized and tin plated for longevity and conductivity purposes.

Again, I had the RV project to look at too, so the DIY route was a no brainer for me. I really enjoyed using the sellers and products I wanted to use, especially on the RV project. It comes down to this...

1. Do you trust the retailer of the kit you are buying to sell you what you want?
2. Is your time and effort more valuable than the cost of the kit?
3. Do you have the time to install a pre-built kit or a DIY kit?

The picture below is of storage area in the RV before I covered it up. This is ~50% of the connections and wiring I did myself, the rest is spread throughout the 5th wheel or on the roof. Clearly, the DIY method saved me thousands of dollars. The truck was the same, but on a much smaller scale.

Good luck with your choice and I am confident you will be pleased with the end result.

 

Thanks for all the feedback and insights. I need to price out the DIY approach for a final comparison and detailed think session.

Does anyone have any reference lengths for the cables? I've not been able to find anything listed yet.

 

i think i have my old one thrown under the bench, i can look later, and get measurements

 

I know I've seen a diagram floating around the internets with the factory measurements in inches, but I can't seem to find it...