what size power cable is optimum to run a winch? it is a 24V low mount if that matters..
does anyone use any special battery terminals, or connect the power lead with the "wing nut" already on most battery terminals?
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cable size / battery terminal to power winch
Moderator: -Scott-
When you're drawing bucket loads of current you want the lowest resistance wire you can install - generally bigger is better.
The two most significant limitations are cable terminations and flexibility. Thicker cables are harder to find suitable terminals for, and the cheaper stuff isn't really flexible, which makes it harder to route.
I'd work backwards from the connection points. Find the largest connectors to fit the various connection points, then buy the most flexible wire I can afford which will fit the smallest terminal. Wherever possible I'd go for crimped connections on the main wire - visions of a screw terminal coming loose at an inopportune time.
Cheers,
Scott
The two most significant limitations are cable terminations and flexibility. Thicker cables are harder to find suitable terminals for, and the cheaper stuff isn't really flexible, which makes it harder to route.
I'd work backwards from the connection points. Find the largest connectors to fit the various connection points, then buy the most flexible wire I can afford which will fit the smallest terminal. Wherever possible I'd go for crimped connections on the main wire - visions of a screw terminal coming loose at an inopportune time.
Cheers,
Scott
Road Ranger
Find some good welding cable. Most insulation is PVC in whatever colour but if you need more flex then rubber insulation can give you that.
Electrical cable is properly rated in the cross sectional area(mm2) of the conductor. 35 or 50mm2 is a good size for what you want.
Work out your cable lengths and then find a local sparky that can crimp some cable lugs onto your cable. A 'die' type (hydraulic or manual)crimper is most preferable, otherwise an indent type (more common) will suffice. It's a five minute job that will look like a million dollars. Best of all - ultra relaible.
They ( the sparky) could supply you the lugs or you could wander into your local wholesaler (ie Rexel, Atkins) and they could supply you (or order) some nice lugs to suit your need. 'Cabac' are a quality lug that are much cheaper than overpriced Utilux stuff. EDIT: Get 'Bell mouth' lugs too, they fit much easier on to flexible cable. You can select a range of termination hole sizes that the lug has too.
Some auto shops like Coverntrys probably sell these aswell, though automotive types. Electrical industry lugs are much higher quality - normally. They're not pricey either, a couple of bucks each.
I personally run 50mm2 flex throughout my Cruiser. It actually HV rated cable but is the most flexible I've seen. It has silicone insulation and rated at 180 degrees. PVC is rated at 75 or 90 and rubber at 90 to 120.
Rubber has the best mechanical protection though. Very hard wearing and probably better for what you want. PVC is not quite as good in this regard but is much cheaper.
Good luck.
Electrical cable is properly rated in the cross sectional area(mm2) of the conductor. 35 or 50mm2 is a good size for what you want.
Work out your cable lengths and then find a local sparky that can crimp some cable lugs onto your cable. A 'die' type (hydraulic or manual)crimper is most preferable, otherwise an indent type (more common) will suffice. It's a five minute job that will look like a million dollars. Best of all - ultra relaible.
They ( the sparky) could supply you the lugs or you could wander into your local wholesaler (ie Rexel, Atkins) and they could supply you (or order) some nice lugs to suit your need. 'Cabac' are a quality lug that are much cheaper than overpriced Utilux stuff. EDIT: Get 'Bell mouth' lugs too, they fit much easier on to flexible cable. You can select a range of termination hole sizes that the lug has too.
Some auto shops like Coverntrys probably sell these aswell, though automotive types. Electrical industry lugs are much higher quality - normally. They're not pricey either, a couple of bucks each.
I personally run 50mm2 flex throughout my Cruiser. It actually HV rated cable but is the most flexible I've seen. It has silicone insulation and rated at 180 degrees. PVC is rated at 75 or 90 and rubber at 90 to 120.
Rubber has the best mechanical protection though. Very hard wearing and probably better for what you want. PVC is not quite as good in this regard but is much cheaper.
Good luck.
thanks for the input.
what about battery terminals, what does everyone do with these? use standard ones and "bolt" the winch cable on to it (with the wing nut / 10mm nut supplied on the standard terminal)? or does everyone use special terminals which can push through good amounts of current?
also, anyone got pics of these special lugs marcop is referring to?
what about battery terminals, what does everyone do with these? use standard ones and "bolt" the winch cable on to it (with the wing nut / 10mm nut supplied on the standard terminal)? or does everyone use special terminals which can push through good amounts of current?
also, anyone got pics of these special lugs marcop is referring to?
Road Ranger
robbie wrote:thanks for the input.
what about battery terminals, what does everyone do with these? use standard ones and "bolt" the winch cable on to it (with the wing nut / 10mm nut supplied on the standard terminal)? or does everyone use special terminals which can push through good amounts of current?
also, anyone got pics of these special lugs marcop is referring to?
Robbie, have PMed you, 35mm is standard and will do the job, but also have 70mm but is overkill. as per PM I can supply with the lugs crimped on and heat shrinked for a prety good price
If the above post did not offend you in any way please PM me so I can try harder!!
Tiny wrote:robbie wrote:thanks for the input.
what about battery terminals, what does everyone do with these? use standard ones and "bolt" the winch cable on to it (with the wing nut / 10mm nut supplied on the standard terminal)? or does everyone use special terminals which can push through good amounts of current?
also, anyone got pics of these special lugs marcop is referring to?
Robbie, have PMed you, 35mm is standard and will do the job, but also have 70mm but is overkill. as per PM I can supply with the lugs crimped on and heat shrinked for a prety good price
robbie, i recently rewired my 12v highmount with 70mm2 welding cable (very flexible). ran one to solenoid box on front, and another to winch body for earth. 24v will use less amps so smaller cable can be used, but my preference for wiring is always use the best available. obviously wouldnt use this to run spotlights tho. next mod will be to put solenoids in sealed box in engine bay and run 4 cables to winch
bought the lugs at rexel, cost $5 each.
hope this helps
Lance
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