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Battery positive cable corroded

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1K views 15 replies 4 participants last post by  tglenn  
#1 ·
Hi,

Noticed the battery light coming on and off occasionally and had observed the battery leads were corroded.

Is it an easy fix, can I just purchase some new cable and chop back and splice? Or should I go to where it terminates?

What gauge cable should I look for? Thinking of doing something like this:
 
#2 ·
There was a time when we would cut the end off and put a new end on it.
That is a solution but IMHO its temporary at best because the simplest terminals tend to loosen.
A better solution is to crimp on a large ring terminal and use a battery connector designed for ring terminals.
The attached video has very solid techniques for making battery cables or in your case replacing the end.
Replacing the cable is difficult for the non experienced, and since you are asking.....
 
#4 ·
#3 ·
What gauge cable should I look for?
You should be good with 6 AWG pure copper welding wire, which is more or less the standard size I've seen. Do NOT buy "copper" wire from Scamazon or Fleabay. Filled with crappy China made CCA (copper-clad aluminum) wire, which has much higher resistance than pure copper.

Temco is a great brand, made in USA.
I think I've bought over 200ft of wires from them so far, for solar RV wiring.

When you make a butt-splice, for the positive wire specifically, you want to be extremely careful and put as much insulation as possible. I'd use marine grade heat shrink tubing and put 3 layers.

Keep the spliced length of wire as close to original length as possible. You don't want to increase voltage drop unnecessarily from longer cables.
 
#10 ·
If you have virtually no wire slack left, that's pretty much your only option.

When I did it, because I also had severe corrosion on positive wire, I stripped the wire back 2 inches (at most), and crimped that to a copper lug.

Because I used a Fastronix battery post, which is longer than factory, I had just a little bit more slack left thankfully.

For your particular situation, here's another alternative I can think of...

Here's the site I used recently to get a whole bulk assortment of reducers for lugs.

For battery wire, this will work up to 4AWG (so you have the option of upsizing if you want):

If you go that route, you won't have to solder or crimp.
You must insulate those VERY WELL, as mentioned earlier. A nick in the positive side wire touching the chassis (shorting the battery, basically) will result in huge sparks and/or fire.

Highly recommended: use Noalox to prevent long term corrosion:
 
#15 ·