MikeR
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| posted on 15/7/18 at 11:07 AM |
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what size battery cable?
So I'm looking at battery cables. I want to take a cable from the battery to the fia switch, then back to the starter solenoid, then on to the
starter. Total length is close to three meters for the positive cable.
Looking at the starter (according to Haynes) it's 2400w at 12v or 200amp by my calculations.
Taking into account amps i think I need flex 35 (11.8mm od, 35mm2 cross section). However adding in voltage drop I'm looking at 50mm cross
section or 13.3mm od.
Does this sound right?
What have you fitted?
Engine is a venerable xflow.
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furryeggs
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| posted on 15/7/18 at 07:08 PM |
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Buy a set of 400A jump leads and cut the clamps off. It should be more than enough and alot cheeaper than battery cable.
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ianhurley20
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| posted on 15/7/18 at 07:46 PM |
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In my case no idea what I fitted - nicked it all of my MX5 donor car - OK for Mazda it will do for me
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SJ
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| posted on 16/7/18 at 09:48 AM |
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Nowhere near that size on mine. I had some what I think are 110a cables kicking about and used those. No issues so far.
Never noticed the cables even getting warm.
ebay link
Stu
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907
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| posted on 16/7/18 at 12:38 PM |
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I used 35mm copper welding cable. Used crimp on lugs to connect to the starter and to the chassis for earth.
Used QR battery terminal connectors.
3m would be under a fiver.
Paul G
p.s. Good for making up quality jump leads as well. Beware cheap aluminium jump leads.
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loggyboy
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| posted on 16/7/18 at 12:55 PM |
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35mm2 (2awg) should be more than adequate.
[Edited on 16-7-18 by loggyboy]
Mistral Motorsport
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furryeggs
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| posted on 16/7/18 at 03:23 PM |
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I had some 200A leads and they got hot when cranking, which would slow after a few turns. Swapped for bigger 400A leads and it cranked alot faster and
they don’t get hot.
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907
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| posted on 16/7/18 at 09:15 PM |
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Do you mean to say that your engine doesn't burst into life the instant you turn the key ?
What you need is an ultra reliable Lotus engine. 
Got a feeling I might regret saying that. 
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Angel Acevedo
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| posted on 17/7/18 at 03:37 PM |
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What is the purpose of your car?
That may lead you to the right answer...
Are you looking for extreme lightness?
Or reliability is a more worthy goal?
Voltage drop coupled to cold weather may lead to extended cranking which is not a good thing on a thinner than desirable cable.
I would go for thickker unless I was racing the car.
HTH.
Angel Acevedo
Beware of what you wish.. for it may come true....
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MikeR
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| posted on 17/7/18 at 10:09 PM |
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Purpose is to pass IVA and get driven for a few miles before I'm too old / broken to do it 
35mm cable is going to be bought - just trying to decide if i get it pre-made or buy a 20 quid hydralic crimper ebay special and cable....
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907
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| posted on 18/7/18 at 12:12 AM |
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quote:
Originally posted by MikeR
Purpose is to pass IVA and get driven for a few miles before I'm too old / broken to do it
35mm cable is going to be bought - just trying to decide if i get it pre-made or buy a 20 quid hydralic crimper ebay special and cable....
No need for special crimpers.
Buy the lead and lugs and use a dot punch or blunt chisel to crimp them.
One supplier even includes a length of heat shrink in the deal.
 
eBay lugs & cable
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big-vee-twin
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| posted on 22/7/18 at 09:15 AM |
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I just bought a set readymade up from Halfords, much less hassle. Been on two years no issues.
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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rusty nuts
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| posted on 22/7/18 at 09:37 AM |
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quote:
Originally posted by 907
quote:
Originally posted by MikeR
Purpose is to pass IVA and get driven for a few miles before I'm too old / broken to do it
35mm cable is going to be bought - just trying to decide if i get it pre-made or buy a 20 quid hydralic crimper ebay special and cable....
No need for special crimpers.
Buy the lead and lugs and use a dot punch or blunt chisel to crimp them.
One supplier even includes a length of heat shrink in the deal.
eBay lugs & cable
I find the above method works well especially if you lay the cable and terminal in a piece of decent angle iron supported in the jaws of a vice
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40inches
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| posted on 22/7/18 at 01:51 PM |
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I made a crimper from bits of scrap, works well.
 
Crimper bits
 
In action
 
Finished
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