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1. Buy a set of reproduction battery cables and you'll end up with the same wire gauge as originally used. That's perfectly adequate.
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2. What I do is use what are referred to as "6 Volt" cables. This just means they are a heavier gauge wire. There will be less Voltage drop during cranking and you may notice the starter spinning more enthusiastically. You can get these at any auto parts store.
And a final note! The original cables were black/negative, brown/positive. If any unfamiliar individuals not paying attention, they could jump your battery battery backward....I know it unlikely! For my car; NOT NCRS, I got heavy cables, #2 RED/positive, BLACK/negative. Also, if you notice most if not all new cars have cables color coded as such. It's a visual thing and it's your car. Dennis
Agree with Jim - I had custom 2 AWG cables made to length & termination particulars to my specs. (OEM is 4 AWG). Believe I still have my drawings & sketches & vendor info around here somewhere, if interested ('66 327, w/out air conditioning).
I make by own battery cables using 1 gauge cable an I have a hydraulic crimper to install the ends and identify them with red and black heat shrink, it is very difficult to buy ready made cables now days with the heavy gauge and having the quality that is required.
OK so no smaller than 4 (OEM) and up to 1 AWG. I will be making my own once the power cut off relay arrives. The longest leg will probably be 18". Thanks
For years I have made my own using type K or M, #1 or #2 AWG welding cable and a crimping tool
Great insulation and very supple compared to regular battery cable.
I like my spring clamp original style from Paragon. I thought it would be a pain to get pliers down above the battery to on/off the clamps, but it isn't bad. Brown is negative.
I make by own battery cables using 1 gauge cable an I have a hydraulic crimper to install the ends and identify them with red and black heat shrink, it is very difficult to buy ready made cables now days with the heavy gauge and having the quality that is required.
Good info. As I do not have a crimper with dies for gauges like this I figure to just shop the Flaps for availability. If no joy, I'll check the local auto mechanic, maybe they have the capability to crimp the end on. If no go there, I will use your resource.
I, too, made my own cables using red for positive 2/0 and black 2/0 for negative. It solved almost all of my starting problems. Just get the wire and the correct sized ring terminal, then crimp them on. I also, later, put a new solenoid in and new Bendix but it starts great now. It is a L79 also with factory a/c so battery is on the driver's side.
The Battery Cable USA site looks great, custom sizing, good pricing and they don't hose you on shipping. Placing an order later today. Thanks for all the responses.
I sourced battery cables for 63 L76 from NAPA. I know you probably ordered already from battery cables site, but if someone searches, maybe this will help.
Thanks Mike, yes I did already order them. As I still have not discovered the origin of my mysterious 1.6 amp parasitic draw my work around was to use a FAA certified master power relay. That is now in the circuit between the battery and the starter. Ordering from those guys afforded me the opportunity to specify the exact lengths I needed at 2 AWG and the specific ends I needed to interface with the relay and starter posts. Couple of days later they were here. Should have them installed today and then maybe, god help me, I'll get some driving in before the snow fly's around here.
Welding and battery cables share many similarities. Compared to other cables, both are flexible, single core, carry the same current or amperage, and have high temperature ratings, up to 105ºC or higher. Despite this, they have several significant differences related to their applications.
What is Welding Cable?
Welding cables are extremely flexible, with a high number of very fine strands made of copper wire. They're insulated with synthetic rubber materials, including ethylene propylene diene monomer rubber (EPDM) and neoprene. The outer covering is relatively soft, abrasion-resistant, and able to handle flexing and abuse. Welding cables retain their flexibility at very low temperatures and withstand high temperatures. You can use welding cables on circuits up to 600 volts.
What is Battery Cable?
Battery cables are relatively rigid, with heavier gauge copper wire strands than welding cables. Insulation materials are PVC and cross-linked polyethylene (XLPE). Battery cables may be difficult to bend, but once formed, they retain their shape. Their insulation withstands arduous under-hood temperatures and is resistant to gas, oils, and lubricants. The voltage rating of battery cables is 60 volts.
Can you use Welding Cable as Battery Cable?
Yes, you can. Welding cables make good battery cables when you need to bend the cable a lot to run it around underbody obstructions. You must support the cable fully so it can't vibrate or touch moving parts. Also, make sure to use corrugated cable protectors to minimize the risk of abrasion. Welding cables make good jumper cables.
No, you should not use battery cables for welding. Many welders have an open circuit voltage that exceeds 60 volts, so it's not safe to use battery cables. Also, a battery cable may kink and snag on obstacles because it's not sufficiently flexible.
Choosing the Right Size Welding or Battery Cable
It is important to select a cable with the correct amperage rating. Also, you need to consider voltage drop over the length of the cable. For vehicle systems, try to keep the volt drop below 0.3 volts. Use the voltage drop calculator to determine a suitable cable for your application in terms of American wire gauge (AWG) size, current drawn, and voltage drop.
It's considered good practice to choose a cable with a slightly greater current rating than required as this reduces the voltage drop, particularly on long welding cables and in 12- and 24-volt automotive systems.
Welding and Battery Cable Specifications
Property Welding Cable Battery Cable Flexibility Very Less so Wire Strands Many, very thing copper wire stranding Fewer, slightly thicker copper wire stranding Temperature Rating -50°C to 105°C (some 90°C) STG: -40°C to 105°C STX, SGX: -40°C to 125°C Voltage Rating Up to 600 volts 60 volts Insulation Materials EPDM, Rubber, Neoprene STG: PVC STX and SGX: XLPE Abrasion Resistance Good Good Oil and Gas Resistance Good Good Flame Resistant yes No
Battery Cable Safety
Safety measures should always be taken when working with a battery cable to prevent future damage. All of our battery cable options meet SAE J-1127, Ford, and Chrysler specifications for use in automotive applications. They also meet UL-558 and UL-553 flame-resistant standards.
Although superficially similar, these cables differ in many respects. These include voltage rating, type of insulation, flexibility, and abrasion resistance. Except in a few instances, it is best to use the correct cable for each application.
Dennis
