Any harm in 2 different wire guages?

[Nan_wpg]

I usually pre order all my wire with lugs (not comfortable yet with my own crimping)

But realize I need to connect my charge controller - to the shunt. Right now it’s on the battery post.

Battery post is 5/16 and shunt posts are 3/8 so my CC - won’t fit. I do have a 4g wire that’s the correct size and it has a 3/8 lug. Perfect.

But that would mean a 6g wire for the CC + and a 4g wire for CC -

Any issues? I’m thinking no issues so long as the wire is able to carry the current (I can go bigger but not smaller).

 

[sunshine_eggo]

No issues as long as you don't exceed the rating of the 4awg wire.

 

[dopeassjackson]

Drill out the ring terminal.

 

[ScropusGobbleBottom]

Drill out the ring terminal.

Make sure its flat after drilling. Burrs be very bad for your health.

 

[robbob2112]

Drill out the ring terminal.

It works, but isn't the same as the correct size ring terminal.

 

[Nan_wpg]

I thought about drilling, but I do,have lugs. I just don’t trust my crimping. I crimp for ground connections, but too paranoid for the power wires.

 

[robbob2112]

So, order a new cable from windy nation or battery cable usa with the correct lugs already on it.

 

[gnappi]

I thought about drilling, but I do,have lugs. I just don’t trust my crimping. I crimp for ground connections, but too paranoid for the power wires.

I bought a crimper and a batch of 100 terminals to test on 8AWG wire and I suck at it. I have the same tool as shown in the youboob videos but they either come out with "wings" on the sides of the crimp or crooked.

 

[LydMekk]

"Wings" are just a sign that the crimp has been made with sufficient force.
No problem.

 

[Nan_wpg]

So, order a new cable from windy nation or battery cable usa with the correct lugs already on it.

I live in Canada. Battery cables ships to us only. I do have a us ship address so I could order cable for the next time I travel down south.

I might just get a local company to crimp me a wire or I’ll buy some cable and practice crimping. I have 3 ground cables to crimp so I. May just do it

 

[dopeassjackson]

"Wings" are just a sign that the crimp has been made with sufficient force.
No problem.

No that's a condition of the wrong crimp or the wrong die used in the crimper.

 

[Daddy Tanuki]

No that's a condition of the wrong crimp or the wrong die used in the crimper.

or a ring terminal that is too big for the wire its being crimped too.

 

[seneysolar]

No that's a condition of the wrong crimp or the wrong die used in the crimper.

Not all the time. My greenlee syncro crimper leaves super thin wings unless you put some oil on the dies. I assume when oiled, the surface doesn't grab and displace material, the terminal just slides into place as its crimped?

I think some of these dies should have polished surface for this reason. I was going to try polishing one on a rainy day.

 

[ericfx1984]

No issues as long as you don't exceed the rating of the 4awg wire.

You beat me to it

 

[DIYrich]

No issues as long as you don't exceed the rating of the 4awg wire.

Isn't the 6g wire smaller?

 

[DPC]

YA buy the right terminals do not drill or modify sometimes things over heat when you remove metal.

 

[DIYrich]

Instead of drilling, cut the end opposite the wire. You keep the same surface area.

 

[Supervstech]

Isn't the 6g wire smaller?

Oh no you DiDnt!

Calling out an eggo oops!

 

[Nan_wpg]

Isn't the 6g wire smaller?

The existing wire from CC to battery is 6g and sized properly. My “replacement” wire is 4g so more than capable.

 

[gnappi]

Thanks for the "wings" replies but I'm stumped

The terminal is not too big as the cable fits snugly into it.

If I use a smaller die I can't close the jaws, a larger die will not crimp and the cable will rather easily pull out.

 

[ericfx1984]

The terminal is not too big as the cable fits snugly into it.

Honestly since the wire gauge is larger than you need you could always reduce the size of the wire at the terminal point if you really need to... Alternatively a gentleman on here showed that if you take a zip tie and put it around the end of the wire you can usually slip The next size or two up of wire into an opening that is just a little too small

 

[DIYrich]

If I use a smaller die I can't close the jaws, a larger die will not crimp and the cable will rather easily pull out.

Buy the right size crimper, or order one cable with the proper size terminal attached.

 

[Pappion]

I use a Hammer Lug Crimper, with a 3lb sledge hammer. 8awg to 4awg. It's rated for that and larger gauges.
Cheap, effective, and no need to fuss with crimp dies. NOT PRETTY. Sometimes I turn the lug over and crimp again.
Hammer Lug Crimper Tool

 

[DPC]

The problem with those types of crimp is they are no longer considered code compliant.
These days they want a crimp that meets consistent standards for a good cold weld.

I still like to use the Pin crimper myself
But your not going to pass an inspection or your insurance will not cover you if the joint overheats and burns your place down.


I would call around and see if Home Despot or other places will rent you a cripmer that you know meets the current regulations and be sure you use the right lugs to fit your wire.

 

[DPC]

And use the right lugs.
Example:

if your using 313 DLO cable for your connections it is except able to use a 400 MCM lug