Kelley's Works in Progress
Electrical Component Data
We can source other sizes of cable for special applications, but in the interest of keeping things simple, we'd prefer to limit selection to 4 gauge, 1 gauge, and 2/0 gauge. The other sizes listed here are for comparison and informational purposes.
These are "suggested" ampacity ratings - we are firm believers in overkill. The usual rule is to figure the maximum current expected in the total circuit, increase that by 10-15%, and then select the next larger wire gage after that.
These are also "constant-duty" ratings - meaning you can plug this much current through this wire for several hours at a stretch. All of these are larger than your OEM wiring, which makes for a larger safety margin.
| Wire Gauge
| 25 Feet
| 50 Feet
| 75 Feet
| 100 Feet
| 125 Feet
| 150 Feet
|
| #4
| 125A
| 100A
| 100A
| 75A
| 50A
| 50A
|
| #3
| 150A
| 125A
| 100A
| 75A
| 50A
| 25A
|
| #2
| 200A
| 200A
| 150A
| 125A
| 100A
| 60A
|
| #1
| 250A
| 250A
| 200A
| 150A
| 120A
| 100A
|
| #0 (#1/0)
| 370A
| 350A
| 200A
| 150A
| 115A
| 75A
|
| #00 (#2/0)
| 480A
| 400A
| 300A
| 250A
| 200A
| 150A
|
| #000 (#3/0)
| 580A
| 500A
| 400A
| 300A
| 250A
| 200A
|
| #0000 (#4/0)
| 625A
| 550A
| 500A
| 400A
| 300A
| 250A
|
So, this gives you an idea what can be carried by this wire. We've selected 1 gauge wire because it's an excellent compromise between pure overkill, shipping weight, and easy handling - most applications just aren't going to overload this stuff. Cables from #2/0 are available by special order, and it's likely that #4 cable will be available soon for "minor" mains and distribution leads - it's good for feeding power to a distribution block at the rear, or for battery relocation projects, but would be considered insufficient for starter mains by our standards.
All connectors used are solid copper, which are packed with Ox-Gard and sealed twice against the environment - first with self-vulcanizing tape, then again with heat shrink tubing. Contamination is the enemy of good connections, and these are built to not get contaminated. Even the OEMR cables aren't made this solid! It is our hope that our battery cables can actually outlast your vehicle!
Do feel free to ask us if you have any questions about our cables - or anything else. We'll do the best we can to make sense of whatever's keeping you up nights...