I get asked

Technical Info and Other Useful Stuff:

Do You Need New Cables?

Battery Cable Tips and Tricks

Different types of Cable Ends

Different Wire Types

What size cable do you need?

Wire size, thickness, amperage

How we assemble cables

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I get asked “Do I need new cables?” fairly often. I’m always puzzled by the question since I can’t really lift the hood and inspect the old ones by email. However there are a few things to look for that are dead giveaways that it’s time for new cables…

Physical Issues:

Corrosion: This is most often caused by the cables being attacked by the sulfuric acid in the battery. Batteries can leak acidic fumes where the battery posts come thru the plastic housing. It can get worse when you get some idiot at the local discount store that beats the battery terminal on with a hammer causing cracks and damage to the fragile seal. Using the battery washers helps create another barrier to the fumes. Sometimes the corrosion is hidden under the insulation. Look for wires that are swelled up near the ends of cracks in the insulation. The green fuzz that forms on the wires is copper sulfate and is poisonous to both plants and animals. Wear safety glasses, gloves and other protective gear and always wash your hands.

Cracked: Cracks in the insulation are points where acid can enter and attack the wire. If they haven't started corroding yet, you can pretty much bet that they will eventually.

Burnt Cables: If the battery cables are too small they can quickly get very hot especially during extended/excessive cranking. Sometimes they get so hot that the insulation actually melts or burns. Also look for insulation that is misshapen or deformed from melting and then cooling into its new shape.

Damaged terminals: If you look closely you will see that this factory lead terminal is cracked. This could be due to many reasons but often it's from over tightening especially if connecting additional wires under the battery bolt. If you need to connect extra wires, buy cables with terminals with extra wire capability or get extra wire nuts/bolts. I tighten them until I can no longer twist the terminal on the post then I go an extra 1/4 or 1/2 turn. To get a good electrical connection, you need a good mechanical connection. It needs to be clean and tight but over tightening doesn’t make it work any better.

Electrical Issues:

Coming soon: How to measure the voltage drop of a battery cable.