Battery cable size

[Dave_Knowles]

Hi,
I am confused as to what size my battery cables should be. At the moment they are I believe welding cable and need to be replaced. My starter motor which is 0.8kw I understand is the key to the size. I have a new alternator which is 60amp and two 110 amp batteries one for starting. These are through a switching unit. The engine is a Volvo AQ151 rated at around 120hp. I do have some new cable which is 50mm sq but is this too heavy? Also I am having trouble putting on the crimping ends if I do use this as the wire seems too big although I am assured that the terminals are for 500mm and they have 50-8 on them.

Dave

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[snowleopard]

firstly the terminal sizes. 50/8 means it will fit a 50mm sq cable, the 8 refers to the size of bolt that will fit through the eye. to make a proper job of these terminals you need a special crimping tool. mine cost £16 so it's not something you'd buy to do a single cable!

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[Rohorn]

Hi......just rewired all mine. 50 mm is a bit big, but if you've got it, and you have room to fit it, why worry. I was also faced with getting special crimper for such large terminals but actually made a very good job of it with mole grip type wrench, adjusted progressively tighter.
Cheers....R

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[Dave_Knowles]

Try as I might I can't seem to get all the strands of the cable in the end is there any tips how to do this? Also where did you get you crimping tool as I am going to have to pay almost that for the hire of one?

Dave

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[Paulka]

West Marine Model 214080 at $ 30.
It will crimp cables from AWG 6 to 4/0 (13 to 107 sq mm.)
Although welding elctrical cables is not recommended, I would not hesitate to weld the terminal directly on a battery cable. It's very easy and quickly done on the stoves flame.
Heat just enough to melt the solder, and not the isolation!

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[halcyon]

If you have 50 mm use 50mm, a few strands not in the terminal will effect nothing, trim them off after. To save crimping, solder it, put connector in vice with cup up, heat with a blow lamp and melt solder in till part filled, flux cable and plunge into end fitting and wait for solder to cool.

Brian

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[steve28]

Just a thought to add to the other coments, if soldering alone is used then be cautious if a survey is carried out as they might not like it.
The reason being if you get a very heavy load or short then the solder will melt and the wire will drop out.

steve

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[Dave_Knowles]

I did wander about this because my daughters land rover had a soldered on connection and this did exactly that, the solder melted and the whole thing got very hot and scary.

Dave

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[charles_reed]

Comes in two diameters, 15mm and 10mm. I find this nomenclature is more widely understood round Europe than quoting cross-sectional area.

The ends aren't crimped but are offered up to the cut end of cable and "screwed" in between insulation and wire.

For most boat needs 10mm is adequate, tho' my battery to starter is 15mm.

The large cross-sectional area is to reduce voltage loss rather than any fear of current causing overheating.

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