Novak Conversions Jeep Wrangler TJ engine mounts

High current cable replacements

nondem

nondem

TJ Enthusiast
Original poster
Joined
Apr 17, 2021
Messages
197
Location
Tallahassee, Fl. USA
Is Amazon sourced 4AWG welding lead cable for the battery going to be better than the OEM stuff that came on my 2003 Sahara? I'm talking about the fine stranded fexible stuff that isn't copper-clad aluminum of course.
I have a bunch around along with lugs from rewiring a golf cart...Figure I could make some new wires and replace the crusty battery connections.
 
I sourced my 2 ga. wire and terminals from a local heavy duty truck parts retailer.
I already had a crimper, shrink tube and Mil-Spec terminal clamps. It's been at least 15 years ago and no signs of corrosion.
And I did use terminal grease prior to crimping and shrink tubing.
 
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alittleoff said:
I sourced my 2 ga. wire and terminals from a local heavy duty truck parts retailer.
I already had a crimper, shrink tube and Mil-Spec terminal clamps. It's been at least 15 years ago and no signs of corrosion.
And I did use terminal grease prior to crimping and shrink tubing.
Click to expand...

Can't argue with 15 year old success...
During my research I read opinions that using dielectric grease between the actual contact areas can increase resistance. I asked AI and it said to make the connection clean and then smear grease over top of it.
The subject competes with "which oil is best" for generating debate :)
 
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Approximately 6 years ago I built cables for my '01 TJ with left overs from a previous XJ project which consisted of 2 ga flexible fine stranded cabling, fusion connectors, military terminal clamps and thick mil shrink tubing (glue inside). Prior to installing the cables in my '01 TJ I shielded them with split wire loom and they have performed flawlessly since then.
 
Last edited:
Just finished making new 2G battery cables for my rig and definitely a worthy upgrade. The crimps from left to right are each reduced 25-30 thousand’s to not distort the barrel area. I also do pull tests with each new gauge cable I’m crimping just to prevent any welding in the engine bay. https://www.batterycablesusa.com/2-gauge-awg-battery-cable-red

Image.jpeg


IMG_1073.jpeg
 
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AVGodZ said:
Just finished making new 2G battery cables for my rig and definitely a worthy upgrade. The crimps from left to right are each reduced 25-30 thousand’s to not distort the barrel area. I also do pull tests with each new gauge cable I’m crimping just to prevent any welding in the engine bay. https://www.batterycablesusa.com/2-gauge-awg-battery-cable-red

View attachment 664442

View attachment 664443
Click to expand...

Those look great. I plan to use the same battery terminal connection....and somewhat follow the Big 7 upgrade I recently read about that replaces all of the grounds and high current connections.
 

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