Need source or info on very short power cable sections

[lesabret1]

I'm laying out the power system components for a teardrop that will reside on a shelf in the tongue box.
Two group 31 AGM batteries on box floor and shelf with 1000 watt inverter/charger, main fuse, master disconnect switch, shunt, solar controller, terminal posts, etc. above the batteries.
The high current carrying portion of the system will be #2 AWG cable between battery bank, main fuse, main switch and inverter/charger.
I want to get some very short pieces of #2 cable with ring terminals and short pieces of buss bar that can connect several of the items placed 2"-4" apart in order to make the layout work in the available shelf space.
I know I can get longer cable sections made that are more like 8" or a foot in length, but then I'd have to space things farther apart than I want and I'd have to try and bend longer pieces of cable in a manner that might violate the recommended minimum radius of the bend per the diameter of the cable.
Anyone know of any source to purchase off-the-shelf or have custom fabricated short sections of #2 cable and equivalent or larger buss bar sections?
Thanks in advance for any guidance.

[halfdome, Danny]

Walmart has a nice selection of battery cables and battery cable ends, etc. in their automotive section.
If you can't find the exact lengths needed you could purchase longer cables and use the ends to make custom lengths.
Danny

[Dale M.]

I would not worry about minimum bending radius .... You could use the longer cable and use 360° "loop around" method of connecting instead of the straight line method..... Really short cable and buss bars require more exact spacing and are not as forgiving if batteries have a little movement while teardrop is in motion... Some times straight line is not shortest path...

Have any electrical suppliers locally that caters to agricultural of manufacturing industry?.... May be a welding supplier/shop can furnish the cable and will crimp ends on ....

Other option may be to make your own.... Cable and "lugs" for ends are readily availabel all you need is good crimper...



http://www.harborfreight.com/hydraulic- ... 66150.html

Dale

[lrrowe]

GeniuneDealz.com will make custom cables. I had them build mine. But 1' is the minimum. Maybe it is a cost thing such that you could ask them to make a smaller one and pay for the 1' as a minimum charge. It is worth a try.

[lesabret1]

Sorry, I didn't explain clearly enough in my original question post . . . there will be a longer length of cable from battery bank up to the shelf to the main fuse.
My interest in the short cable or buss bar sections is for the remaining components on the shelf to be connected together.
The shelf will be sort of a "circuit board" for the other components, spaced in close proximity to one another.
The cables from the battery bank to the shelf will be longer, with service loops to allow the shelf to be unhooked, lifted up and placed on top of the box rim, in order to provide access to the batteries when needed. I'm planning on about 2 ft. of cable from battery bank to shelf (main fuse) with about another 1 ft. In overall length from fuse to inverter/charger, including components in order to keep total length from battery bank to inverter/charger at 3 ft. (6 ft. Including both positive and negative cables).
Thanks for the info on GenuineDealz.com, I'll check them out.

[lrrowe]

Sorry, I didn't explain clearly enough in my original question post . . . there will be a longer length of cable from battery bank up to the shelf to the main fuse.
My interest in the short cable or buss bar sections is for the remaining components on the shelf to be connected together.
The shelf will be sort of a "circuit board" for the other components, spaced in close proximity to one another.
The cables from the battery bank to the shelf will be longer, with service loops to allow the shelf to be unhooked, lifted up and placed on top of the box rim, in order to provide access to the batteries when needed. I'm planning on about 2 ft. of cable from battery bank to shelf (main fuse) with about another 1 ft. In overall length from fuse to inverter/charger, including components in order to keep total length from battery bank to inverter/charger at 3 ft. (6 ft. Including both positive and negative cables).
Thanks for the info on GenuineDealz.com, I'll check them out.

Here is what they built for me. And they spent a lot of time with me to make sure we had the order specs correctly stated.

[lesabret1]

Here is what they built for me. And they spent a lot of time with me to make sure we had the order specs correctly stated.
[/quote]

Bob, what gauge wire are the cables in your picture.
I'm looking for short pieces of #2 AWG cable with 5/16 ring terminals crimped on the ends.

[lrrowe]

Mine were 4 ga. I wanted 2ga also, but the largest size the PD 4045 would take is 4 ga. (Per the manufacturer).

[rowerwet]

Ask around your nearest airport for a maintenance shop, aircraft mechanics fabricate battery cables all the time. Also marine shops

[lrrowe]

I never considered Marine shops. I have a good acquantance who owns one. I will ask him about it the next I see him.
Thanks for the tip rowerwet

[martymcfly]

A few years ago, I did an EV conversion on a VW Bug. I used a lot of 2 ot cable. To run between the batteries, I used the bolt on side terminals. I just took the bolt out and used the wing nut that came on the batteries. Some ends needed lugs crimped on to bolt on to contactor or controller or motor, I took them to the nearest Interstate batteries place. They crimped the lugs on and heat shrinked them for me. The charged me less than $10. I had supplied the lugs and cable though. I couldn't have bought a crimper for that.

[rowerwet]

While it may not suit everyone, I have crimped terminals for an airplane using vicegrips. Wrap the teeth in tape, then put a small Phillips screw driver 90 degrees to the wire. Crush the screw driver shaft into the center of the top of the terminal socket. Knowing how deep to crimp is the key.
I may or may not have done this when nothing else would work, to get somebody home...

[Esteban]

GeniuneDealz.com will make custom cables. I had them build mine. But 1' is the minimum. Maybe it is a cost thing such that you could ask them to make a smaller one and pay for the 1' as a minimum charge. It is worth a try.

Like lrrowe I intend to have www.genuinedealz.com/custom-cables make custom cables for my teardrop. When I know what lengths and wire gauges are needed I'll order custom made battery cables to run between the battery and the Progressive Dynamics PD4045-45-Amp-Inteli-Power-Mighty-Mini-Power-Center.