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Where to find custom battery cables?

kaw700zn

Jr. Member
Joined
Apr 24, 2012
Messages
134
Loc.
Chandler
I want to relocate the solenoid for my winch inside of the engine bay. The original cables are too short, so I am planning to get new, longer cables (7 feet). Some cables need 90 degree lug while others just straight lug. I was hoping to find prebuilt cables but I can't find any. I really don't want to build my own cables if I don't have to. I don't want to buy a crimping tool for 8 lugs. Any ideas?

While there, if you have your winch solenoid relocation pictures, please post them.
 

gr8scott

Contributor
Bronco Guru
Joined
Jul 1, 2011
Messages
1,890

sykanr0ng

Bronco Guru
Joined
Aug 11, 2014
Messages
5,363
Why relocated your winch's solenoid?

Under the hood:

1. Out of the weather.

2. If you can lock your hood no punks can power your winch on after running your cable / line over the roof to your back bumper.
 

KBUCK1

Sr. Member
Joined
Feb 8, 2011
Messages
979
I bought a moroso cable set from summit. Cut to the length you need and install ends. No crimping tool needed. Has a compression nut to hold the lug on
 

pcf_mark

Bronco Guru
Joined
Jun 11, 2010
Messages
3,696
I used welding cable bought from my local welding store. Then once I had them the length I wanted I took them back and they crimped the lugs on for free (lugs were extra but no labor). Welding cable is much more expensive because it is very fine strands to make it flexible.
 

73azbronco

Contributor
Bronco Guru
Joined
Nov 11, 2007
Messages
8,778
HF hydraulic crimp tool works great, about $50. Andsolder it.
 

71broncman

Sr. Member
Joined
Sep 6, 2009
Messages
410
Loc.
Maysville, Ky
When I worked at CARQUEST some of the stores had the equipment to make custom cables. May also try a heavy equipment repair facility.
Mark.
 

DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
51,617
There are companies that make custom sets for you as well. We make them at Wild Horses within reason, and up to 2ga. You may need larger depending on just how long each segment is, but 2ga can get you pretty far.
If you need to go more, there is Wrangler Power Products (their old name) or Wrangler NW, but if they still offer that stuff you either need to figure out their website or just download their catalog.
Probably not worth it, when you can get custom battery cables at so many places.

For your lengths I would use 2ga as a minimum standard. Longer needs larger, so 1, 1/0 and 2/0 are not out of line. I had Wrangler make cables for my Bronco and pickup 20 years ago out of welding cable and they're still doing great.
Welding cable is neat, and is very flexible and slightly smaller diameter in most cases vs standard cable for a given gauge. But there are some legitimate negatives that have been written about as well. Not enough to keep me from keeping rolls of it on hand in 1/0 and 8 gauge for making my own, but worth reading about.

When I'm doing a simple re-wire though, I find it very convenient to run down to the local parts store and pick up 2ga pre-made versions in the lengths I need. Then I shrink tube the ends at the eyelets to keep the weather out. Then I cover them for about 7/8ths of their length with corrugated high temperature rated split-loom for abrasion resistance, chemical contamination protection (lasts a little longer, but not a cure for carelessness) and they look cool too.

And they're very stout, inexpensive and work well.
But once you get the lengths you need, give us a call to see if we can make you what you need.
This is what ours look like for the standard off-the-shelf set: http://www.wildhorses4x4.com/product/Custom_Battery_Cables_Set/Bronco_Batteries

Good luck.

Paul
 

BanditBronco

Sr. Member
Joined
Jul 2, 2008
Messages
690
Looks like you are in AZ, hit up Tony from CEautoelectricsupply.com Tell him Riley sent you and he will take care of you. Both my tow rig and Bronco have custom cables from him, he is the man!
 

Unaweep

Full Member
Joined
Sep 11, 2013
Messages
215
Loc.
Grand Junction CO
:Do
I used welding cable bought from my local welding store. Then once I had them the length I wanted I took them back and they crimped the lugs on for free (lugs were extra but no labor). Welding cable is much more expensive because it is very fine strands to make it flexible.

This.
 

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Yup, welding cable FTW.

The posted videos are great, but I prefer to have more physical clamping force holding the cable in on a 4x4 that bounces around.

I like to place the cable in the lug, place on setup on an anvil and use a center punch in the center to basically clamp the cable into the lug. I then place the cable lug in a vide and drill a small hole in the empty cavity where the lug tapers to the mounting surface. Heat it up and push solder into it until it comes out the back. Let it cool a bit and then heat shrink the end on. I've never had a cable come apart doing it that way -

I ran -2GA from the battery to the rear of the Bronco in preparation of a dual battery setup I was going to run in the back. I got it from the welding store and it was relatively cheap compared to every other option I found.
 
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