Wiring in a Battery Switch

[skybolt_1]

I'm wiring in a battery switch and a combination buss-bar into my sailboat. There was no pre-existing switch, the previous owner was content to simply disconnect everything from the screw-terminals on the battery before he left the boat.

I purchased a Bluesea battery switch and Dualbus Plus with 5/16ths lugs to do this. However, I'm totally unwilling to pay West Marine prices on battery cables (something like 35 bucks for 4-5 feet) so I went to my local auto parts store. They only had cables with 3/8" holes in them, suggesting that I just use washers to make up the difference. This doesn't seem that electrically sound.

Granted, I don't have any high-draw items on the boat, just little stuff like lights, radio, and the outboard starter (which gets its own set of lugs on the Dualbus). But I don't know if I should keep shopping for cables with lugs that are 5/16".

Is it the end of the world to use cables with 3/8" holes in them on 5/16" terminals?

Thanks!

 

[Silvertip]

Re: Wiring in a Battery Switch

No. But rather than use regular washers and wing nuts, pitch them and use stainless internal or external tool washers and stainless nuts. You will have better and more reliable connections. As for the cables, you can buy terminal ends and bulk cable. I will get chastized for suggesting soldering but crimp and/or solder the new lugs to the appropriate length cable. Add heat shrink over the junction on the cable ends to provide additional protection for moisture.

 

[skybolt_1]

Re: Wiring in a Battery Switch

OK, so basically just go with stainless hardware and "real" nuts and I should be fine?

I will be checking on this regularly, its not as if I intent to entomb the battery far away from where I can reach it. I will probably also give a quick WD-40 spray over the terminals to help drive out latent moisture.

 

[Silvertip]

Re: Wiring in a Battery Switch

Yes.