[chbot] Heavy cable, terminations & crimp tool to replace golf cart cable

[Robin Gilks]

Further reading indicates that most carts are wired with #6 cable - in
other words 4mm, 13mm^2. That would appear to be the case with mine but
with 30 years of corrosion in the cables they get nice and toasty after
half an hour.
Recommendations are to go to #4 (5mm, 21mm^2) with no need to go bigger
unless upgrading to a much bigger motor/controller.
I'm not convinced. Put your foot down to start towing a full grass sweeper
and it pulling north of 100amps @ 36v so I'm inclined to go with minimum
6mm (25mm^2) with no objection to 8mm (35mm^2). The bigger the cable the
less loss twixt battery & motor (and at 36v you can't afford to loose
10-20v like with a mains circuit!!)
All terminal lugs are 8mm as far as I can see (reversing switch and
batteries at least).

The main stumbling block is one battery terminal stud that had an 8mm nut
forced onto a 5/16 stud (or vice versa - not clear) so the stud just turns.
The stud is actually a bolt moulded into the lead post with the head at the
bottom where you can't get to it. I'm hoping a 3mm hole drilled in from the
side will allow me to wedge it enough to undo the nut. I really don't want
to splash out $350 for the sake of one bolt!

Cheers

On Fri, Dec 8, 2023 at 8:12 AM Mike Smith <mikesmith25 at gmail.com> wrote:

> There is a seller on trademe in rangiora called ev-hardware that is
> cheap for cable, cheaper than I can buy trade
>
> I have the tools to crimp cable up to 240mm if you need them
>
> Mike
>
> On Thu, Dec 7, 2023 at 6:17 PM Stuart Brown <stuartbrown2 at gmail.com>
> wrote:
> >
> > Robin
> >
> > Try one of the electric fork lift charger outfits, like Stanbury or
> Enatel. If they can't sell you cable, and help you crimp connectors,
> hopefully they could give you some names.
> >
> > Stuart
> >
> > On Thu, 7 Dec 2023 at 15:07, Robin Gilks <gb7ipd at gmail.com> wrote:
> >>
> >> Title says it all really - looking for 200amp cable, about 10m of it
> (between batteries & battery -> controller -> reversing switch).
> >>
> >> Golf carts are very much designed for intermittent operation (working
> up the fairway) rather than kms with a weed sprayer or pulling a grass
> sweeper so the reversing switch needs replacing (gets too hot to touch) and
> some of the cables get very soft and flabby with heat.
> >>
> >> Switch is $250-$300 so looking to not spend too much on cables (but not
> rubbish AliExpress aluminium wire that has a copper coating!!). The main
> part of the exercise is quality!
> >>
> >> Ideas on where to get the parts at a reasonable price and if anyone has
> a big crimp tool I could borrow that would be great (I used to get one from
> Taits but I doubt they have that sort of kit now)
> >>
> >> Cheers
> >>
> >> --
> >> Robin Gilks
> >> marathon golf cart switch
> >>
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