Cable question

Hey, gully!

Are you looking for 4g, or do you want even bigger? BU has a nice 4g kit for Fleet carts that I think would work, but you would have some extra cables since you are PDS. If you want larger than 4g I think you will need to fab them.
 
A couple years ago I wanted to go to 2ga and bought the cable and shrink wrap, but was never able to get the ends I was suggested to get……so I kinda lost interest in the project. I was never able to find a good crimper that was cost effective for the one time project as well. So now I’d just rather buy a set or have somebody make me a set with what I have.
 
Gully,

Don't need a crimper. I soldered mine:
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The pellets work great. I used a small machinist's vise to hold the lug upright, a few drops of flux on the bare wire and in the lug, drop a pellet in, heat lug with a propane torch. Pellet melts, slowly lower bare wire into lug, keep heat applied for 2-3 seconds and remove heat while supporting the wire till the solder sets. Apply the shrink wrap and you're done. No wasted tools. And a GREAT connection!
 
Or....... Get a flat concrete chisel, insert your wire into the lug, place on a 2x4 on the garage floor and whack the holy hell out of it with a big hammer. Might not be as pretty as a crimper or solder but it's a good connection and won't break loose.

This is the way I used to do 0/0 stereo power cable before I started eating Grey Poupon and became more civilized
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Thanks gornoman thats what I'll do!! I looked and I guess it was 4ga welding wire that I got. Now I just have to figure out what size eyelet I need for the terminals. Are they all the same size for the batteries, motor and controller??
 
You'll need 5/16 eyelets on all the cables. There's two smaller ones on the motor that you won't have to change on a PDS cart.
 
I just dug out my spare parts box and some of the 4g copper lugs have 5/16" holes and some have 3/8" holes. Guess you will need both, and I cannot give a count as my cart is 90 miles away.
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I am new to the forum but I thought I may throw my two cents in for the cables. I recently went to the electrical supply store and purchased 0 guage wire and they gave me an electrical connector for electrical panels. This connector simply screws down to the wire and has a hole for the post of the battery to pass through. I had to drill it a bit oversize to fit the post but it worked like a champ and noticed a siginicant torque increase right away. Now I have to see the result after the rest of the cables are changed.
 
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