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Old 05-03-2011, 08:39 AM   #1
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What size wire for battery hookup?

I have a 91 350LE. I just replaced the chassis battery and the 2 coach batteries with group 27 Lifeline AGM batteries. The original cables will not work with this set up so I need to custom make some cables. What size wire should I use? Steve G
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Old 05-03-2011, 09:24 AM   #2
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Old 05-03-2011, 09:42 AM   #3
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Larger IS better in battery cables!

I never usually install anything less than 2/0, but for one engine battery 0-AWG should work fine. Depending on the amp draw from your house batteries, you could probably use 0-AWG also, but I prefer more wire than less to eliminate any potential problems. Also, ask for welding cable for your new batteries as they are much more supple and flexible than standard battery cable.

Did you get a GPL-2700T starting battery for the engine and GPL-27T deep cycle for the house units?
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Old 05-03-2011, 09:42 AM   #4
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Quote:
Originally Posted by t7389sg View Post
I have a 91 350LE. I just replaced the chassis battery and the 2 coach batteries with group 27 Lifeline AGM batteries. The original cables will not work with this set up so I need to custom make some cables. What size wire should I use? Steve G
I use 4 Gauge for my house batteries.. Made my own. I bought the crimper at a local electrical supply house. I bought the end at a welding supply shop.
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Old 05-03-2011, 10:22 AM   #5
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Battery Hook Up

When connecting batteries in parallel try to run the house positive from one battery and the negative from the other battery. This guarantees that both batteries are used. If it is wired as this picture, a dirty connection on the second battery will result in only the first battery doing the heavy work. Just reverse the wire hook up on the negative in the picture and you have a fail proof connection.
Dave


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Old 05-03-2011, 12:53 PM   #6
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Larger IS better in battery cables!

I never usually install anything less than 2/0, but for one engine battery 0-AWG should work fine. Depending on the amp draw from your house batteries, you could probably use 0-AWG also, but I prefer more wire than less to eliminate any potential problems. Also, ask for welding cable for your new batteries as they are much more supple and flexible than standard battery cable.

Did you get a GPL-2700T starting battery for the engine and GPL-27T deep cycle for the house units?
Yes. two 27T & one 2700T My problem stems from the origial starter battery being a side teminal and the new Lfeline batteries have recessed top post so the flag terminals do not fit well.
I think I will just order some welding 2/0 cable/wire and use military terminals. Thanks for your help.
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Old 05-04-2011, 10:14 PM   #7
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..........I think I will just order some welding 2/0 cable/wire and use military terminals. Thanks for your help.
What's a military terminal?
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Old 05-05-2011, 01:02 AM   #8
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Here's some examples...

ordance battery terminal - Google Search


It allows you to use 3/8" eye terminals end on your battery cables...
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Old 05-05-2011, 06:58 AM   #9
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When I rewired my trailer I used 4 gauge from each battery in to a block like this. From this I used 1/0 like this. This wire is very flexable and is much finer wire than welding cable. They also carry battery terminals that are rated to use up to 3/0ga.

I was able to purchase all the parts I needed at a local car audio shop for less than $100.

BTW: I have no intrest in the company I listed. It's just what I used.
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Old 05-05-2011, 08:10 AM   #10
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When I rewired my trailer I used 4 gauge from each battery in to a block like this. From this I used 1/0 like this. This wire is very flexable and is much finer wire than welding cable. They also carry battery terminals that are rated to use up to 3/0ga.

I was able to purchase all the parts I needed at a local car audio shop for less than $100.

BTW: I have no intrest in the company I listed. It's just what I used.
The class K welding cable that I use for most hi power transmission use is basically the same thing, just without the fancy jackets. It is comprised of many very fine conductors wrapped in either black or red thermoplastic elastomer which is extremely flexible and rated to 221*F and is rated for heavy duty use. Much more flexibility than regular battery cables, which I replace on a regular basis.
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Old 05-05-2011, 08:34 AM   #11
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I used some surplus server grounding cables - very flexible because of the large number of fine strands. For connectors I used bolt-on cable lugs; I like these because they're reusable and can be retightened if needed.

- Bart
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Old 05-05-2011, 08:51 AM   #12
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I just ordered these



plus 6 feet of 2/0 welding cable black and red. I plan on installing the teminals and then make short jumpers to connect all the batteries. I think the military terminals are better than the marine type because the marine type have wing nuts on top and that may sit too high to close the drawer. Thanks for all the responces to this post. Steve G
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