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I guess I submitted my original post in the wrong Forum a few days ago so Dan V., suggested I repost here. Thanks Dan V.!
I'm about to upgrade to a 250 amp high-output alternator to accommodate some of the new accessories on my truck and trailer and the new unit requires a Big Three Wire kit to handle the extra current along with the original wiring configuration. While looking under the hood, I thought it would also be a good idea to change out all the old battery cables and also install a new Power distribution Kit so I could cleanup some of the bird-nest wiring mess connected to both batteries. I spent a few hours looking at battery cable replacement kits on the web and the outrageous prices made me break a sweat for a sec and pucker-up my You-Know-Where; just the battery cable kit prices range anywhere from approximately $325-$450 while the necessary big three alternator wiring kit is another $95. I'm pretty handy so I decided instead that I'm going to purchase the materials and make the cables myself.
During my expedition through the Interwebs, I was able to figure out the wire lengths and the wire gauge for the new "Big-Three" alternator wiring kit so that bulk material is currently sitting in my shopping cart. I was also able to figure out the approximate length and gauge of the new cables on the Power Distribution build so that material is also in my cart. With that said, I was unable to find any information on wire lengths or diagrams and schematics illustrating the correct wire length and gauge for the new battery cable replacement kit for everything I'm going to replace under the hood. By chance, is anyone here familiar with the battery cable replacement Kit, and know the length and gauge size for each of the cables in the kit? I'm almost certain there's six cables in the kit. My goal is to tackle the whole job in a day, install new Power distribution and reroute all accessory cables from both batteries to the new fuse box, install new alternator and connect Big-Three cable kit to handle the extra current, and install the new battery cable wiring kit. Since it's going to take several hours to make ALL of the new cables, I'd like to have everything pre-built and on-hand before I remove any of the old harness from the truck. So, friends, if anyone has any data on battery cable lengths and gauge for the said, replacement kit, possible you can share?
All the main wiring you will want 2/0 cable. Many use welding cable for this. I use an oversized 1/0(which is basically 2/0) pure OFC cable. Do not get CCA cable. There is a reason why kits or cable is so expensive, the pricing you listed above seems low and I question the quality of the cable.
I also use tinned copper cable and lugs, this helps prevent corrosion in areas where water/ moisture will be. My purpose for upgrading was for my stereo system; so I use quality audio cable; which is not exactly cheap either. I purchased 50ft spools of both power/ ground cable. I also made a run with an anderson connector for jumper cables and will do the same when I add a winch.
I have a hand crimp tool that works great but is not exactly cheap either.
I'll see if I can get a link to the crimper I use, you may be able to find a cheaper chinese version on amazon, IDK. SHCA cable lug crimper
I would like to do the same thing because of the same reasons. I'd really appreciate it if you would please share your final order/material details, or a pointer to where to find. Thank you.
Ancor tinned copper off Amazon is the best price/cable you’ll get. No point not going tinned copper especially cost when we are talking 1 truck…for a Decent crimper probably looking at 140-220 hex is preferred. At the same time there’s gorillas out there using a sledge hammer to crimp lol
have used this one recently did good of course when your a pro at over thinking still would have rather used a hex crimp.
I used welding cable, much more flexible than battery cable.
For connectors I use FTZ power lugs, those are made to survive the worst environments...think trawler 30 ft waves north Atlantic type environment
I used welding cable, much more flexible than battery cable.
For connectors I use FTZ power lugs, those are made to survive the worst environments...think trawler 30 ft waves north Atlantic type environment
Not absolutely sure since it's been a few years, think the starter cable is 3/0, all other battery cables were 1/0. Tried my best to go up at least 2 sizes. Look at Bay Marine Supply for the FTZ power lugs, best quality lugs that I can find, and they adhere to the industry standard.
Got my cable from Temco, they have an eBay store ..US manufactured, they also carry semi -professional crimpers
I used 2/0 welding cable on everything, starter cable, thr crossover cable , the grounds…….which means that “if” I ever install a larger HO alternator all that is left is to increase the size of the alternator wire.
I am a welder by trade, take a close look at this ampacity chart:
Take note of two things!
1. Your cable length to the starter will be nowhere near 50’
2. And even at 50’ the ampacity of 2/0 welding cable is 450 Amps. Your run will be much shorter which means a higher ampacity than what is given at 50’ (Dont believe me? Follow the chart using the same size cable but different length runs and ampacity’s)
Also take note that a starter motor has a duty cycle…….. you don’t just crank and crank and crank…….unless you want to burn it up
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