Starter Cable Gauge? - TCCoA Forums

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post #1 of 9 (permalink) Old 03-10-2017, 02:27 PM Thread Starter
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Starter Cable Gauge?

I have to repair the starter cable. Too short and frayed. I plan on butt splicing and adding 6 inches and putting a better terminal on the battery. Just curious if you guys knew the cable gauge so i can start this amazon order. Thanks in advance!

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Last edited by Tokuman; 03-10-2017 at 02:32 PM.
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post #2 of 9 (permalink) Old 03-10-2017, 05:55 PM
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IIRC, the stock cable is 4 gauge. I'd really suggest making a new cable rather than splicing onto the original.
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post #3 of 9 (permalink) Old 03-10-2017, 09:35 PM
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Quote:
Originally Posted by racecougar View Post
IIRC, the stock cable is 4 gauge. I'd really suggest making a new cable rather than splicing onto the original.
This.

Also, nothing wrong with going 2ga or even 0 or 00 ...

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post #4 of 9 (permalink) Old 03-11-2017, 01:59 PM Thread Starter
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I'd love to run a brand new cable. I thought maybe a butt splice + better terminal would be better than one of those splice kits. I have 5 cars and this one needs the most work and need to prioritize the transmission slipping, oil leaking, suspension work, bleed brakes and of course the current issue of the car not starting. I have ruled out the battery (advance says it's good and it starts my grand marquis) and the engine isn't seized.

I searched through TCCOA and found people were successful with the short term splice kits. I thought I'd do a short term fix to get the car moving and then have all the supplies and tools to do it the right way in the future. Would I be putting myself in imminent threat of hazard?
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post #5 of 9 (permalink) Old 03-12-2017, 01:34 PM
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Quote:
Originally Posted by Tokuman View Post
I'd love to run a brand new cable. I thought maybe a butt splice + better terminal would be better than one of those splice kits. I have 5 cars and this one needs the most work and need to prioritize the transmission slipping, oil leaking, suspension work, bleed brakes and of course the current issue of the car not starting. I have ruled out the battery (advance says it's good and it starts my grand marquis) and the engine isn't seized.

I searched through TCCOA and found people were successful with the short term splice kits. I thought I'd do a short term fix to get the car moving and then have all the supplies and tools to do it the right way in the future. Would I be putting myself in imminent threat of hazard?
I agree with the other member that recommended 2 gauge or bigger. With 5 cars, you should make the small investment in some bulk wire, cable ends, and a heavy duty crimp tool. It will save you money and you'll have higher quality and better fitting cables.

I keep cable lugs on hand with many different sizes of holes (#10, 1/4", 5/16" 3/8", etc) and then put marine type screw down ends on my batteries. Makes it super easy to remove, which also allows me to quickly swap batteries from one car to another. Having good batteries in a bunch of vehicles you don't use often enough results in lots of bad batteries (unless you have trickle chargers running to them.)

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post #6 of 9 (permalink) Old 03-13-2017, 12:50 AM
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Personally, I agree with everyone else here in that just splicing the cable is throwing money away.

I agree about the recommendation to buy a crimp tool and connector ends but as far as bulk wire is concerned, I've found that welding shops and some battery places will sell super flexible thick gauge (4, 2, 0) cable by the foot which you can buy on an as-needed basis as each project comes up.

If you are on a budget and need a long thick battery cable for a given project (say a battery relocation), E30s have their battery in the trunk and are wired with 1/0 cable (or something in that range of thickness).

-g

PS. If your starter cable is getting frayed, don't neglect proper grounding if you are having a hard time starting the car. On my tbird track car, I ran a separate ground cable from the starter mounting bolt back to the battery.
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post #7 of 9 (permalink) Old 03-13-2017, 10:38 AM
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post #8 of 9 (permalink) Old 03-13-2017, 01:01 PM
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Did someone say upgraded wiring?? This is 2/0 welding cable with soldered copper lugs. I agree that you should replace the cable rather than splice it.
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post #9 of 9 (permalink) Old 03-14-2017, 04:49 PM
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Quote:
Originally Posted by S4gunn View Post
Personally, I agree with everyone else here in that just splicing the cable is throwing money away.

I agree about the recommendation to buy a crimp tool and connector ends but as far as bulk wire is concerned, I've found that welding shops and some battery places will sell super flexible thick gauge (4, 2, 0) cable by the foot which you can buy on an as-needed basis as each project comes up.

If you are on a budget and need a long thick battery cable for a given project (say a battery relocation), E30s have their battery in the trunk and are wired with 1/0 cable (or something in that range of thickness).

-g

PS. If your starter cable is getting frayed, don't neglect proper grounding if you are having a hard time starting the car. On my tbird track car, I ran a separate ground cable from the starter mounting bolt back to the battery.
Welding wire is great. Its made of many more fine strands than standard battery cable and that makes it fleible. Whe i said bulk, i wasn't suggesting a roll of 500' but i like to keep 20' on hand. Welding shops sometimes do not always have cable ends with small enough holes for standard auto use. Theirs are often 3/8" which is usually too big. I can't think of one to recommend but there are plenty of places with these available with 5/16" or smaller holes. they also make ends that have set screws to hold the wire but these cost more and after buying them a few times you'll have spent as much extra as a crimp tool would cost.

Ihave a Standard Motor Products hammer type crimper - @ 35, and a hydraulic type kit which i found on ebay for $40. The hydraulic has the advantage that if you are making a cable while one end is still attached in the car, you don't need a solid surface where you can hit the crimper with a hammer.

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