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Cable FAQ

We offer a highly flexible fine strand welding cable that is excellent for upgrades on electric vehicles, for either battery cables, or complete cable kits. It has an external insulation rated to 600 volts.

Understanding Confusing Cable Size Numbers
Cable size is standardized by it's AWG number (American Wire Gauge). The higher the AWG number the smaller diameter the cable, i.g. 6 AWG is smaller than 4 AWG. All cables smaller than 1 AWG are called "gauge", i.g. "I need 6 gauge cable". The next size larger than 1 gauge is 0, which is written as 1/0 and called "1 aught", i.g. "I need six feet of 1 aught cable". Bigger sizes add zeros; 00 size is written 2/0 and is called "two aught".

AWG Internal Cable Diameter
6 .1620 4.115
4 .2043 5.189
2 .2576 6.544
1/0 .3249 8.251

How Big Do Your Cables Need To Be?

All your big cables need to be the same size, your battery cables, to your motor controller and to your motor (regen type motors have two wires that can be smaller). Just upgrading your battery cables is not enough because your motor can pull more amps than your batteries do. On most golf cars the stock cable size is 6 AWG cables. Note that the insulation on modern cable is thinner than the older style, which leads people to mistakenly believe they already have big enough cables on their golf cart. So the outside diameter of your cables is not a good indication of your actual cable size.

Normally you will choose your cable size based on your motor controller amperage. Here is a general guideline. If your vehicle has long cables these sizes may need to be increased:

300 amp systems = 6 AWG cables
400 amp systems = 4 AWG cables
500-600 amp systems = 2 AWG cables
600+ amp systems (hunting buggies) - 1/0 AWG cables

Why We Crimp Lugs VS Solder
All of our cable kits have solid copper tinned lugs that are crimped instead of soldered. Correctly crimped, the copper lug and wire become fused into one piece of metal. Tests show that crimping (VS soldering) is stronger and longer lasting under tension and heat. The aerospace industry uses crimping, as does Siemens motors.