Battery and cable layout

[ModedCB2]

Also avoid "welding cable" the heavy-thick strand stuff for arc welding cables. It will get hot and when formed can kink/break much more easily that fine stranded cable. You can get decent "car audio" type 1/0 or 0/1 on ebay for $2-$4/ft.

The trick with the pre-made kits is that they cheap out on welding cable for the long runs and that is where you will have higher losses that the voltage drops listed above.

I did an experiment a year or so ago. I took my 220v mega-ancient arc/stick welder and made brand new cables:

First using traditional welding 1/0 cable. When at 60% cycle I had one of the cables accidently laying across my ankle. It left a 2nd degree burn on my skin. also I couldn't handle the cable with a mechanic's gloved hand for several seconds.

Next I used some average, find strand Car audio 1/0. Same identical O.D. but looking at the strand structure you can tell it has less outer coating and more actual wire. Same test. I could more the cable with my bare hand. It was still VERY warm to the touch, but not searing into my skin.

Personally I would run 1/0 for the back to front main run to a junction, with circuit breaker at the battery side. Then a 0/1 to the starter, separately breakered.

I have built many systems over the years and I have typically saved $$ versus the performance gain over the "kits". I buy my optima mounting brackets, circuit breakers, wire, cable ends, etc mainly on eBay. just easier to get exactly what you want for your install.

here are some links to places to buy:

circuit Breakers:
http://stores.ebay.com/Bag-Boy-Home-...&_sid=14969603

1/0 0 gauge
http://stores.ebay.com/Bag-Boy-Home-...=p4634.c0.m322

www.darvex.com Trail is the guy's name. He is a GREAT guy. Fellow enthusiast. He's in arkansas, so semi-central location. ships same day... bag-boy on ebay is Darvex.

But you can find (2) packs of circuit breakers on ebay for $25.



Lastly, I would say this: as a Certified Car Audio Installer and wiring street rods and muscle cars for 20+ years... the flexibility ALONE of fine strand wire is worth the $1-2/ft difference in price. Working with welding cable in a car is a pain in the butt getting it tucked into corners, around edges etc.

Rob