DIY big 7 upgrade - have some info, need some info

[DeltaNu1142]

I started thinking about doing this a few months ago when I stumbled on batterycablesusa.com. I have no affiliation with this company... they're just a US manufacturer of quality battery cables. They'll custom-make any gauge cable you want, with whatever ends you want. So I decided I was going to measure up everything and compare pricing to jeepcables.com.

Both of these companies are here in the US. At the time I started this, I didn't know where jeepcables.com was, and depending on the results I might end just going with their pre-assembled kit. In any case, I don't see any reason to buy garbage from another country when we can keep our money here.

Here's what I've got so far:

Cable	Length	End 1	End 2
Battery to fuse block	13"	battery +	1/4" (M6)
Battery to alternator	21"	battery -	5/16" (M8)
Battery to engine block	34"	battery +	? lug on engine block
Battery to firewall	44"	battery -	? large lug on firewall
Battery to starter	26"	battery +	? lug on starter
?	?	?	?

I'm missing some lug sizing from my tables. If anyone knows those, it would help a lot. I could remove the lugs to measure, but what I gathered above just took me 15 minutes before work.

I've got 5 cables here. I understand the pre-assembled kits add a fuse, so that makes 6. I'm missing something... is it the engine block to the frame? I'll have to look for that one.

Also, can anyone tell me where this green-sheathed cable goes? It connects the fuse block to... somewhere:

At the time I'm posting this, it's $120 for a 4-ga pre-assembled kit from jeepcables.com delivered to my door. For the same size from batterycablesusa.com in their "extreme" line, I'm up to $69 shipped for the five cables above, battery terminals, and boots. No fuses or other cables yet.

An argument could be made that it's not worth the effort to go through all this when I can just buy the kit and install it. And a lot of times, that's 100% true. But I'd rather know than guess, and if this saves somebody a couple bucks even better.

 

[macleanflood]

I bought a big 7 kit thinking I'd get a right angle lug for the PDU after deciding it was toouch trouble finding one I could crimp myself. Kit didn't come with one... pretty disappointed.

Personally I'd make my own next time.

-Mac

 

[DeltaNu1142]

Kit didn't come with one... pretty disappointed.

Huh. Good to know. You still have a '97? I checked out an install video, and it looked like on the later models the cables ran straight into the PDU and attached to the two lugs at the back end, no angles needed.

 

[mudmaster]

it looked like on the later models the cables ran straight into the PDU and attached to the two lugs at the back end, no angles needed.

Correct. I installed on my 06 without any issues.

 

[Siwash89]

Did tou ever figure out the setup for the equivalent aftermarket cable set? Like what the lengths and parts are for the fuse? Also what connectors are used for the engine block, firewall and alternator? Be awesome if you updated this with the full information. Good reference

 

[DeltaNu1142]

No - I’ve been distracted with other stuff lately. I posted what I had in hopes that someone else could fill in some blanks.

 

[MikekiM]

I did the Big-7 kit.

Didn't make sense to try to cobble stuff together. Off the shelf was a perfect fit.

 

[DeltaNu1142]

I'm probably going to end up doing that, too. What got me started on this is the batterycablesusa.com site. It's dead easy to have them pre-make cables for you.

 

[Siwash89]

I did the Big-7 kit.

Didn't make sense to try to cobble stuff together. Off the shelf was a perfect fit.

Dont have to cobble stuff together if we got the correct measurements and parts needed to assemble a kit. And it cost a good bit less than buying a “kit”.

Maybe after you buy the kit you can update this thread with all the measurements?

 

[DeltaNu1142]

I started this thread with at least a little consideration to the work that jeepcables.com put into developing their off-the-shelf kit. There's a special place in hell for IP thieves, and while just measuring the cables and all of the lugs from their kit would be easiest... it just doesn't feel right.

I know the end result is the same, but the way you get there holds at least a little meaning to me. All of the measurements above, I took off my Jeep. If anyone else wants to contribute info, cool. If not, that's OK too. I just don't want to feel like I'm stealing from a vendor to save a couple of bucks.

 

[Siwash89]

Solid reply.

When i get around to doing this, maybe i will update the thread with what i use. Thanks

 

[jjvw]

Dont have to cobble stuff together if we got the correct measurements and parts needed to assemble a kit. And it cost a good bit less than buying a “kit”.

Maybe after you buy the kit you can update this thread with all the measurements?

You already have a factory kit. Measure and copy that. And while you do that, try to figure out what problem is addressed by increasing the wire size.

 

[Rut Row]

FWIW, I bought the Zen kit from custombatterycables.com. They I had them make custom 1/0 cables for my winch.

https://custombatterycables.com/product/jeep-wrangler-tj-i-6-6-cyl-4-0l-1997-2006-1ga-zen-13027/

 

[bbaldwin237]

I'm curious how much this would actually save in the end, not even counting your time. I do understand some people have lots of time, just really enjoy doing everything themselves, or may need to save any amount that they possibly can, where they can. The Jeep Cables kit is just under $150 for my '97 in 2ga without added sleeving. It comes pre built with labels and is ready to go. To me, that seems pretty good for what you are getting as far as someone else doing the research and work, not having to buy specialty crimpers (if you don't have them) and making them look nice. Then you still need the other little bits, terminal clamps, hardware, rubber boots, etc. Those little parts are going to add up. Not a lot of Jeep parts come in under $200 these days.

 

[jjvw]

I'm curious how much this would actually save in the end, not even counting your time. I do understand some people have lots of time, just really enjoy doing everything themselves, or may need to save any amount that they possibly can, where they can. The Jeep Cables kit is just under $150 for my '97 in 2ga without added sleeving. It comes pre built with labels and is ready to go. To me, that seems pretty good for what you are getting as far as someone else doing the research and work, not having to buy specialty crimpers (if you don't have them) and making them look nice. Then you still need the other little bits, terminal clamps, hardware, rubber boots, etc. Those little parts are going to add up. Not a lot of Jeep parts come in under $200 these days.

In the interest of saving money, what is value of increasing to 2awg wire?

 

[Siwash89]

You already have a factory kit. Measure and copy that. And while you do that, try to figure out what problem is addressed by increasing the wire size.

Going to a larger alternator i can see a benefit.

 

[Siwash89]

I'm curious how much this would actually save in the end, not even counting your time. I do understand some people have lots of time, just really enjoy doing everything themselves, or may need to save any amount that they possibly can, where they can. The Jeep Cables kit is just under $150 for my '97 in 2ga without added sleeving. It comes pre built with labels and is ready to go. To me, that seems pretty good for what you are getting as far as someone else doing the research and work, not having to buy specialty crimpers (if you don't have them) and making them look nice. Then you still need the other little bits, terminal clamps, hardware, rubber boots, etc. Those little parts are going to add up. Not a lot of Jeep parts come in under $200 these days.

Did you look at batterycablesusa website? The cables are pre made however you want. And its looking like $80 for a setup identical to what your explaining.

 

[bbaldwin237]

In the interest of saving money, what is value of increasing to 2awg wire?

I mean yes, if your goal was saving money, then you would probably stick with 4ga. And for what it's worth, that kit is $107 from Jeep Cables. Hard to see much room for savings on doing that yourself.

And for what it's worth, 4ga is probably enough for 90%+ of TJ applications. 2ga is what it defaults to on their website so I was just using that as a middle of the road (price wise) example.

 

[bbaldwin237]

Did you look at batterycablesusa website? The cables are pre made however you want. And its looking like $80 for a setup identical to what your explaining.

No I missed that one up there. I mean if you're comparing same gauges, $70 isn't a nothing. But I would bet if you stuck with the 4ga that gap would get smaller ($107 on Jeep Cables).

And of course, everyone gets to do things their own way. But sometimes you see these DIY options cost as much (I've even seen more) than buying a product that is already offered. Doesn't make it right or wrong for each person, just saying.

 

[Siwash89]

Well im going to look into it and find out if its worth it cost wise.

160a durango alternator
250a ANL fuse
2g battery cables and military terminals