Electric winch power cables...................................

Submitted: Monday, Jan 12, 2009 at 14:35
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When I transferred the Brawn 9500 over to the GQ from the G60 I just cable tied the power box to the side of the winch with the remote plug-in inside the engine bay next to the radiator.

Anyway, I have been doing stuff in and around that part of the vehicle and see that one cable has chafed through the rubber coating. So thought I had better tidy up this lot, once and for all.

Have decided to put the power box inside the engine bay. This will mean lengthening the power cables. Had a look around town today but Jumper Lead cables are too thin. Found some positive Arc Welding cable on a roll sold by the metre. Looks sturdy albeit pretty expensive.

Anyone care to comment on using this?

BTW I am 250km away from the Big Smoke so Bunnings, Super Cheap and all those wonderful places you have are all too far away. Have to make do here in the scrub


Cheers
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Reply By: Sir Kev & Darkie - Monday, Jan 12, 2009 at 14:37

Monday, Jan 12, 2009 at 14:37
A couple of strands of the trusty 8 gauge fencing wire painted red should do it LOL

Cheers Kev
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Follow Up By: Member - Tour Boy (Bororen) - Monday, Jan 12, 2009 at 15:00

Monday, Jan 12, 2009 at 15:00
Better make that 12 gauge as he will be winching a poootrol.,.LOL
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Dave
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Follow Up By: Willem - Monday, Jan 12, 2009 at 15:15

Monday, Jan 12, 2009 at 15:15
Can always rely on a practical idea from Kev...........................LOL




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Follow Up By: Member No 1- Monday, Jan 12, 2009 at 21:24

Monday, Jan 12, 2009 at 21:24
it must be painted red willem if you want it to work
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Follow Up By: Pete Jackman (SA) - Tuesday, Jan 13, 2009 at 13:39

Tuesday, Jan 13, 2009 at 13:39
The earth will have to be painted black or the electric steam may go the wrong way and winch you further into the bog.
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Reply By: get outmore - Monday, Jan 12, 2009 at 14:40

Monday, Jan 12, 2009 at 14:40
Winchs are the most power hungry things youve got
- I wouldnt be lengtheining the cables - it doesnt take much of a power drop to reduce the effectivness of the winch
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Follow Up By: Willem - Monday, Jan 12, 2009 at 15:16

Monday, Jan 12, 2009 at 15:16
Yep , that is a consideration.
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Reply By: Vince NSW - Monday, Jan 12, 2009 at 14:54

Monday, Jan 12, 2009 at 14:54
Willem

What length do you need ? May have some out back in the warehouse

Vince
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Follow Up By: Willem - Monday, Jan 12, 2009 at 15:17

Monday, Jan 12, 2009 at 15:17
Thanks Vince. Will let you know.

I thought you were on holidays in the Northern Hemisphere?


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Follow Up By: Vince NSW - Monday, Jan 12, 2009 at 15:36

Monday, Jan 12, 2009 at 15:36
Still in Oz. Fly out 30 Jan foe 7 cold days working in UK and get back on 9 Feb. Then only 19 day and I am a free man.

Let me know how long & what gage you need. We have the elecs here in the morming and if I can't find a piece, I will put the bite on them as they owe me a few .

On another front. Got the Codan up & running like a treat (for it's age)

Vince
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Reply By: Robin Miller - Monday, Jan 12, 2009 at 15:01

Monday, Jan 12, 2009 at 15:01
Hi Willem

My Brawn 9500 soleniod pack , is mounted at top of battery on standard Patrol , between battery and mudguard.

This keeps it out of mud but has the disadvantage that you need an extra 2 meters of heavy duty cable.

The cables to the winch need to be a bare minimum of 25mm sq copper and preferrably 32mm.

32mm is called 2 gauge - and your welding wire can do the job
if its this gauge or better.

I got rid of controller and took the wires back to couple of switches on dash so I can operate winch while in driver seat.

Robin Miller

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Follow Up By: Willem - Monday, Jan 12, 2009 at 15:15

Monday, Jan 12, 2009 at 15:15
Thanks Robin will go down and measure the thickness of the cable at our Rural Hware place.

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Follow Up By: Peter_n_Margaret - Monday, Jan 12, 2009 at 15:30

Monday, Jan 12, 2009 at 15:30
Willem, try to get a 'proper' swageing tool to put the terminals on with, otherwise you risk a high resistance joint that might get hot.

Cheers,
Peter
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Follow Up By: Willem - Monday, Jan 12, 2009 at 15:41

Monday, Jan 12, 2009 at 15:41
Thanks Peter. I will keep that in mind.

I usually make up my own cable ends with copper pipe.


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Follow Up By: Member - Tony B (Malanda FNQ) - Monday, Jan 12, 2009 at 17:10

Monday, Jan 12, 2009 at 17:10
Willem - Thats what I like to see, why buy when you can make? Got that train of thought from my Granfather a Blacksmith. Never thought of it, but copper pipe would make excellent terminals - Ta for that. Cheers Tony
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Follow Up By: Geoff (Newcastle, NSW) - Monday, Jan 12, 2009 at 22:14

Monday, Jan 12, 2009 at 22:14
Hi Willem,
Just a quick followup to Robin's great advice.

You may be offered welding cable in either 25sqmm or 35sqmm cross sectional area in the copper and single or double insulated in the sheath.

(2 gauge B&S is imperial and very closely converts to 32sqmm in SI (metric))

My suggestion would be to pick the 35sqmm double insulated stuff. (Slightly bigger than Robin's great suggestion in imperial and the nearest SI equivalent)

I always use double insulated welding cable for my full current battery applications. The stuff is "almost" boiler maker proof.

Geoff
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Reply By: Maîneÿ (wa) - Monday, Jan 12, 2009 at 17:47

Monday, Jan 12, 2009 at 17:47
Here only for consideration...

What about using 32mm² cable or Welding cable if at least similar size, run from battery to a heavy duty relay, then out to winch.

This would be a distance probably 1 Mtr. ??
Image Could Not Be Found

The activation cable only has to be of a nominal size, as it does not carry the 100 Amp current.

Mainey . . .
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Follow Up By: Member - Kiwi Kia - Monday, Jan 12, 2009 at 18:11

Monday, Jan 12, 2009 at 18:11
Hi Mainey,

Do you think that a 100 amp contactor is heavy enough ? My winch draws 65 - 70 amps just reeling in a loose cable. Single pull near stall draws about 165 amps.

.
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Follow Up By: Maîneÿ (wa) - Monday, Jan 12, 2009 at 18:58

Monday, Jan 12, 2009 at 18:58
Kiwi,
Have not a clue, as they all differ, as I said it's only posted for consideration, and I think this is considered as just that :-)

If it needs 165 Amps then use one rated @ 200+ Amps

Mainey . . .
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Follow Up By: Member - Kiwi Kia - Monday, Jan 12, 2009 at 20:41

Monday, Jan 12, 2009 at 20:41
Do you know if they are vailable (12 volt / 200 amp) ?

.
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Reply By: autosparky - Monday, Jan 12, 2009 at 21:29

Monday, Jan 12, 2009 at 21:29
you did not ask you could have had that too!!!!!!!!!!!
AnswerID: 343986

Reply By: Eric Experience - Monday, Jan 12, 2009 at 21:45

Monday, Jan 12, 2009 at 21:45
Willem.
Most trucks run very heavy battery leads, so if you know where there is an old truck in someone's paddock go and pinch, sorry borrow the cables of it. Eric
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