Marine Cable vs Welding Cable (1 Viewer)

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SATJS

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I am installing a 2nd battery and am at the point that I need to buy the cables. I've decided on 1/0 for both the power and ground between the batteries and ACR 7622. I've spent hours researching this site and others, and am still torn between marine cable and welding cable. I've read that the 1/0 welding cable is less heat resistant, but everything I've found is rated at 105C, which is the the same as the marine cable. The only real difference I can find is the marine cable has 1064 strands of 30awg copper and the welding cable has 1016 strands of 30awg copper, and the marine cable is tinned. The cables I'm referring to are both EWCS. I can get 15' of black and 15' of red welding cable, which is enough for my needs, for $74.80, or 25' of each in marine cable for 199.60. Is the extra 48 strands and the fact that it's tinned make the marine cable worth twice the cost? I don't mind spending the extra if necessary, but don't want to waste money if there is little or no benefit. I will also be using wire loom on all cables for added protection. Thanks in advance for any opinions or advice. Here are links to the cables

https://www.amazon.com/Approved-Mar...d=1470610713&sr=8-3&keywords=1/0+marine+cable

1/0 AWG Premium Extra Flexible Welding Cable 600 Volt COMBO PACK - BLACK+RED - 15 FEET OF EACH - EWCS Spec - Made in the USA! - - Amazon.com
 
From my experience of using 1/0 wire, having it pre-tinned is a nice advantage (I didn't have that and had to tin them myself which takes a lot of heat). Marine wire is usually rated for "wet" applications or in areas that are prone to moisture. I believe it's also a requirement that marine cables be self-extinguishing in the case of fires (correct me if I'm wrong though). Welding cable is made to be a bit more flexible so that the welder doesn't have to lug around heavy stiff wires everywhere. I have seen it swell up when exposed to oil for some reason which is odd. Not sure about the amount of strands but the way I understand resistance in electrical circuits is if there are more paths - or at least wider paths if you're speaking in terms of the gauge - for the electrons to flow through then there will be less resistance. Also look into crimping and then soldering as well. I did both after receiving from feedback from this community and the crimped + soldered connection provides a more solid and durable connection between the lug terminals and the wire itself.
 
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Tinned = minimal corrosion if any
 
Welding cable is rugged stuff and used for RV applications regularly. Anything with "marine" in the name usually costs a bunch more. Boat owners get soaked. :bounce: Quality of the cable matters a lot. Buy from a reputable company. Tinned is nice if soldering it, but a good crimp is an excellent connection and will be fine. I get all my electrical equipment from Arizona Wind and Sun.
 
I work on antique electronics fairly often. Tinning wire isn't a big deal, the entire cable being tinned is. In a marine environment tinned wire is essential to a long, corrosion free life. That said, I don't think any of the wire in an LC is tinned other than at a solder joint. If it was me, I'd use tinned cable with the realization that it's probably gross overkill unless I decide to drive to Europe :)
 
I 2nd what @duggy says. I have read some people are concerned w/ welding wire not being rated to handle gas/oil.. but I've had it wired up to my alternator for a few years and have no problem whatsoever. Cheaper, more flex-able, and the stranding is better. I crimp my ends and then apply liberal amounts of solder to tin the end.. then wrap with headshrink. Go to a welding supply store, and they will have the lugs and wire in many gauges.
 
The West Marine website recommends NOT soldering the lugs as it increases the possibility of broken strands due to lack of flexibility at the joint. They say to spray with Fluid Film and then crimp which is what I did. And I used their tinned cable, lugs, and heat shrink tube with the glue inside. No issue so far.
 
What do you do with the "wad" of connections on the positive cable when you change it out?

p1972928756-4.jpg
 
Thanks for all the replies, definitely seems to be a debatable subject. I'm leaning toward going with welding wire at this point. It seems to me that if I use marine lugs, adhesive lined heat shrink, and sleeve the cables, they should be safe as far as abrasion, heat, fuel and oil, etc. i'll still be losing the tinned wires and a few strands of copper. Since I'm going with 1/0 cable, which most on these boards say is somewhat overkill anyway, losing 50 out of over 1000 strands shouldn't make that much difference. I'd still appreciate any more opinions or arguments that anybody may have as many of you have vastly more experience and knowledge on this subject than me.
 
Mike6158,
One way is to just take a piece of copper bar, drill a hole in each end, then twist it 90 deg. in a vice. That's all I did.
Like so......

misc 015.jpg
 
Another option is get one of these terminal extensions and a military terminal from our good friends at Slee Offroad. The copper bar trick looks like a great idea too, but for less than $20 this was an easier option for me. It probably makes more sense for me since I can just drive over to Slee and get stuff when I need to. It only shows up on Slee's website as part of the group 31 battery tray, but they will sell it separately.

Terminal Extension.jpg
Terminal Extension 2.jpg
 
SATJS said:
I am installing a 2nd battery and am at the point that I need to buy the cables. I've decided on 1/0 for both the power and ground between the batteries and ACR 7622. I've spent hours researching this site and others, and am still torn between marine cable and welding cable. I've read that the 1/0 welding cable is less heat resistant, but everything I've found is rated at 105C, which is the the same as the marine cable. The only real difference I can find is the marine cable has 1064 strands of 30awg copper and the welding cable has 1016 strands of 30awg copper, and the marine cable is tinned. The cables I'm referring to are both EWCS. I can get 15' of black and 15' of red welding cable, which is enough for my needs, for $74.80, or 25' of each in marine cable for 199.60. Is the extra 48 strands and the fact that it's tinned make the marine cable worth twice the cost? I don't mind spending the extra if necessary, but don't want to waste money if there is little or no benefit. I will also be using wire loom on all cables for added protection. Thanks in advance for any opinions or advice. Here are links to the cables

https://www.amazon.com/Approved-Marine-Tinned-Copper-Battery/dp/B00TANRAN8/ref=sr_1_3?ie=UTF8&qid=1470610713&sr=8-3&keywords=1/0+marine+cable

1/0 AWG Premium Extra Flexible Welding Cable 600 Volt COMBO PACK - BLACK+RED - 15 FEET OF EACH - EWCS Spec - Made in the USA! - - Amazon.com
Click to expand...
I'd pick the welding cable over the marine for reasons mentioned above. Tinned conductor wouldn't be a deal-breaker...check your oem battery cables some time.

I'd look at aircraft wire, maybe M16878/16. You'll get no issues with oil exposure, and a far smaller cable diameter for easier routing.

The difference in stranding is approximately the same as a 13awg wire...no functional difference you'd see. Difference is probably due to different specs needed in welding, v. USCG specs for marine installations.

As to terminating the cable, crimp lugs with a tool recommended by the lug manufacturer is the way to go. Fracture of soldered joints is not uncommon, and soldered joints may not be gas-tight, like a properly crimped joint.

Heat-shrink with adhesive lining sometimes has issues with a good waterproof bond to welding (neoprene) cable. What may help is abrading the cable with 180 grit paper, and cleaning the abraded area with an aggressive solvent (acetone, brake cleaner, etc.). Continue cleaning the abraded area until your shop towel is free of black crap.

hth

Steve
 
Im good with welding cable based on cost and experience. I had 3/0 welding cable run through the frame of my 60 series providing rear winch for 10 years plus and never a problem and still looks great and usable hanging on the garage wall.
 
SATJS said:
Another option is get one of these terminal extensions and a military terminal from our good friends at Slee Offroad. The copper bar trick looks like a great idea too, but for less than $20 this was an easier option for me. It probably makes more sense for me since I can just drive over to Slee and get stuff when I need to. It only shows up on Slee's website as part of the group 31 battery tray, but they will sell it separately.

View attachment 1304662 View attachment 1304663
Click to expand...

What is the cost of that part, <$20?
How much addition length does it provide? Enough to use the more popular opposite post battery?
 
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SATJS said:
Another option is get one of these terminal extensions and a military terminal from our good friends at Slee Offroad. The copper bar trick looks like a great idea too, but for less than $20 this was an easier option for me. It probably makes more sense for me since I can just drive over to Slee and get stuff when I need to. It only shows up on Slee's website as part of the group 31 battery tray, but they will sell it separately.

View attachment 1304662 View attachment 1304663
Click to expand...
x2 on the cost^^
Really like that terminal extension bracket, I didn't realize Slee sold those. I'm looking to upgrade to an X2 Power battery in the near future and this would be nice to have considering I have winch, stereo, and lights wired to the positive terminal. This would definitely help clean everything up. Might be looking at a Blue Seas fuse box too now that I think about it...
 
LandCruiserPhil said:
What is the cost of that part, <$20?
How much addition length does it provide? Enough to use the more popular opposite post battery?
Click to expand...
Price for the extension was right around $10, by the time you add the military style terminal it gets up the the $18-$20. As far as the opposite post battery, it doesn't provide much extra length, maybe 1". I don't think it would be enough
 
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I you go with Marine wire - check out Genuinedealz.com you can order the wires pre made to length with whatever size lug you need. Its overkill but they have great service for way less than a most places.

I have used them a couple times and the service has always been 5 star
 
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