Custom Battery Cables

Technical data and wire gauge charts. 

Note: I got the following information from a variety of sources.  I have not personally verified the data shown.

AWG
Size
Insulation
Thickness
Diameter Approx.
Weight
6 65 mils 0.333 in. 116 lbs./1000'
4 65 mils 0.360 in. 158 lbs./1000'
2 60 mils 0.440 in. 244 lbs./1000'
1 60 mils 0.480 in. 304 lbs./1000'
1/0 65 mils 0.520 in. 370 lbs./1000'
2/0 65 mils 0.570 in. 458 lbs./1000'
3/0 78 mils 0.660 in. 586 lbs./1000'
4/0 78 mils 0.740 in. 779 lbs./1000'

 

Allowable Amperage of Conductors for Under 50V (Per SAE J-378)
Note: Since most wire is rated at 85�C use the 80�C values.

Conductor Size
(AWG)

Inside Engine Spaces
67�C
(140�F)
75�C
(167�F)
80�C
(176�F)
90�C
(194�F)
105�C
(221�F)
125�C
(257�F)

18

5.8 7.5 11.7 16.4 17.0 22.3

16

8.7 11.3 15.6 20.5 21.3 26.7

14

11.6 15.0 19.5 29.8 35.6 45

12

14.5 18.8 27.3 32.8 38.3 44.5

10

23.2 30.0 39.0 45.1 51.0 62.3

8

31.9 48.8 54.6 57.4 68.0 80.1

6

46.4 71.3 78.0 82.0 102.0 111.3

4

60.9 93.8 101.4 110.7 136.0 151.3

3

69.6 108.8 117.0 127.1 153.0 173.6

2

81.2 127.5 136.5 147.6 178.5 200.3

1

95.7 146.3 163.8 172.2 208.3 235.9

0 or 1/0

113.1 172.5 191.1 200.9 242.3 271.5

2/0

130.5 198.8 222.3 233.7 280.5 316.0

3/0

150.8 232.5 257.4 270.6 327.3 364.9

4/0

174.0 270.0 300.3 315.7 378.3 422.8



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Revised: 03/28/14.