TheSamba.com :: View topic

Thu Nov 20, 2008 3:06 pm

What is the best guage wire for a positive battery cable. Using a Optima yellow top battery and 75amp alternator. Dont like any of the ones I have found out there so I thought I would make my own
Thanks Ed

Thu Nov 20, 2008 3:49 pm

Mine were made from 2 gauge.

Thu Nov 20, 2008 3:56 pm

Call Kymco and order one from them

http://www.thesamba.com/vw/classifieds/detail.php?id=506404

Thu Nov 20, 2008 6:01 pm

Lookin for something alittle more custom looking than standard battery cables
Thanks though

Thu Nov 20, 2008 6:08 pm

you cold buy a battery terminal and then use some really thick 8 or even 4 gauge wire used for car audio installs. for that custom look you can get in either like semi-transparent (can see the strands inside) red, blue, or black, that would be something a lil different

Thu Nov 20, 2008 6:36 pm

oldbug wrote: What is the best guage wire for a positive battery cable. Using a Optima yellow top battery and 75amp alternator. Dont like any of the ones I have found out there so I thought I would make my own
Thanks Ed

I'm running 2 gauge as well. The guys at Batteries Plus made my set up for me.

Thu Nov 20, 2008 7:44 pm

If for some reason you are drawing a full 75 amps from the alternator, at least 8 gauge wire is needed to handle the amperage. Going larger won't hurt it a bit, but won't help it either.

Find some 8 ga (or larger) wire that you like, and go with it.

The pair of your headlights on "high" are only drawing 8.5 amps of power (assuming 60 watt bulbs and 14 volts from the alt). To be drawing a full 75 amps from the alternator would be the equivelant of 17 1/2 high beam head lights running all at once. That's a HUGE load that the alternator can deliver!

Fri Nov 21, 2008 7:49 am

How "custom" do you want it? I went side mount and was able to use some trickier components…

Fri Nov 21, 2008 10:25 am

Maimas13 wrote: you cold buy a battery terminal and then use some really thick 8 or even 4 gauge wire used for car audio installs. for that custom look you can get in either like semi-transparent (can see the strands inside) red, blue, or black, that would be something a lil different
I think thats what I am going to go with, 4 gauge transparent wire
Thanks for the help everyone

Fri Nov 21, 2008 1:20 pm

marekv8 wrote: How "custom" do you want it? I went side mount and was able to use some trickier components…

Man, that's sweet! Good job. Why are there three brake fluid reservoirs?

Fri Nov 21, 2008 4:04 pm

There are three Tilton master cylinders, each with a remote reservoir. The front and rear brake systems each have their own and the third is for the hydraulic clutch.

Fri Nov 21, 2008 4:48 pm

marekv8 wrote: There are three Tilton master cylinders, each with a remote reservoir. The front and rear brake systems each have their own and the third is for the hydraulic clutch.

More pics... I need more pics. That car is totally awesome. I can't wait to see the engine.

Fri Nov 21, 2008 4:59 pm

marekv8 wrote: There are three Tilton master cylinders, each with a remote reservoir. The front and rear brake systems each have their own and the third is for the hydraulic clutch.

VERY impressive :shock:
Well done. Nice attention to detail. 8)

Fri Nov 21, 2008 5:21 pm

yeah, look at his gallery. I have bug envy.......

Fri Nov 21, 2008 6:32 pm

marekv8 wrote: How "custom" do you want it? I went side mount and was able to use some trickier components…

Dude,
I just checked out your gallery pics. Your name isn't Jay Leno is it?

Sat Nov 22, 2008 8:41 am

If you are looking to improve your battery connections you might consider the following.

The stock 12V VW battery cable is 25 MM2

4 AWG cable is smaller than the stock 25MM2 battery cable.

Don't replace the stock 25 MM2 with anything smaller than 2 AWG.

If you double the length of your battery cable to relocate the battery, you want to use cables with 1/2 of the resistance, or twice the cross sectional area of the stock cable, so your voltage losses won't be any greater.
--------------------------------------------------------
25 MM2 has 1.25 X more resistance than 2 AWG

25 MM2 has 1.63 X more resistance than 1 AWG

25 MM2 has 2.06 X more resistance than 1/0 AWG (0AWG)

25 MM2 has 2.60 X more resistance than 2/0 AWG

25 MM2 has 3.28 X more resistance than 3/0 AWG

25 MM2 has 4.12 X more resistance than 4/0 AWG
---------------------------------------------------------

The stock 6MM2 metric sized cable used for your alternator is larger in diameter than 10 AWG, but not as large as 8 AWG.

For a 75 Amp alternator you might want to consider using 6 AWG to reduce voltage losses.

25mm2 on top, 1/0 AWG (0AWG) on bottom. 1/0 AWG has 1/2 of the voltage losses of the stock 25MM2 battery cable.

I found a spool of this 1/0 AWG (0AWG) 105 degree C rated cable at a surplus store for $.50/foot. The black cable on top of the spool is the stock 25MM2 battery cable

Scott Novak

Sat Nov 22, 2008 8:58 am

Eaallred wrote: If for some reason you are drawing a full 75 amps from the alternator, at least 8 gauge wire is needed to handle the amperage. Going larger won't hurt it a bit, but won't help it either.

Find some 8 ga (or larger) wire that you like, and go with it.

The pair of your headlights on "high" are only drawing 8.5 amps of power (assuming 60 watt bulbs and 14 volts from the alt). To be drawing a full 75 amps from the alternator would be the equivelant of 17 1/2 high beam head lights running all at once. That's a HUGE load that the alternator can deliver!

My bad. I was thinking the main wire from the alternator to the battery. Battery to starter would need to be at least stock size.

Fri Nov 28, 2008 4:54 pm

marekv8 wrote: How "custom" do you want it? I went side mount and was able to use some trickier components…

What guage wire did you use for your battery set up
Ed

Sat Nov 29, 2008 11:18 am

but that looks to me like 4 awg

Sat Dec 06, 2008 4:36 pm

Decided on 4 gauge positive and negative
Thanks for all the help
Ed