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Battery Pack Cabling Kits

Next, choose the Interconnect Kit that matches your drive system and battery post style. This kit includes the cable and hardware to connect each battery to the next one in the pack. Order one Interconnect kit for each battery. We recommend ordering one extra Interconnect Kit for spares.

For "L" or Flag posts, please confirm hole size. Most are 5/16", but some are 5/16" on one post and 3/8" on the other, so check BOTH posts.

The items in the kits are also sold separately. See price list for pricing of both kits and individual parts.

To make a proper crimp:

• Cut the cable to length.
• Strip the insulation from the end.
• Fill the lug or clamp barrel with Noalox Anti-Corrosion Compound.
• Crimp lug or clamp onto cable
• Cover joint with heatshrink tube.

For batteries with "L" or Flag style posts, excellent interconnects can also be made from flat copper strap. Strap 1" wide by 1/16" thick is the equvialent of 2/0 cable, but is lighter and sometimes easier to fit between very close battery posts. It does not need lugs. Each strap should have at least one bend in it, to allow it to flex with road vibrations and not stress battery terminals. It is recommended to slip the heatshrink tube onto the strap BEFORE making the final bend for ease of handling, then heatshrink it into place AFTER the final bend is made.

To make a copper strap interconnect:

• Make a pasteboard mockup first to determine length and bend locations.
• Cut copper strap to length.
• Drill & deburr holes for bolts.
• Make bends in vise.
• Insulate strap between battery posts with heatshrink tube.

Belleville washers are precision tension convex washers that keep battery connections tight without the severity of split ring washers.

Basic Cabling Kits for Components:
1 Per Vehicle

	NetGain/Curtis DC System	HiPer Drive AC System
Includes: Cable for Components Cable Shears Cable Crimper Noalox Heatshrink Tube Lugs for Components: Motor Controller Contactor Circuit Breaker Shunt Spares	$242.75 30'- 2/0 Cable 1 - Cable Shears 1 - Cable Crimper 1 - Noalox 2'- 3/4" Heatshrink Tube 2/0 Lugs:    4 - 3/8" hole    3 - 5/16" hole    2 - 3/8" hole    2 - 3/8" hole    2 - 3/8" hole    2 ea.- 3/8" & 5/16" hole	$244.50 30'- 2/0 Cable 1 - Cable Shears 1 - Cable Crimper 1 - Noalox 2'- 3/4" Heatshrink Tube 2/0 Lugs:    3 - 5/16" hole    5 - 5/16" hole    2 - 5/16"" hole    2 - 3/8" hole    2 - 3/8" hole    2 ea.- 3/8" & 5/16" hole

Interconnect Kits for Batteries:
1 Per Battery + 1 Spare

Battery Post Style	Kit Includes:	NetGain/Curtis DC System	HiPer Drive AC System
"L" Posts or Flag Posts (Recommended)	For Cable Interconnects: Cable Heatshrink Tube Lugs for Battery Posts Belleville Washers	$9.90 1'- 2/0 Cable 3"- 3/4" Heatshrink Tube 2 - 2/0 Lugs 2 - Belleville Washers (Confirm hole sizes for lugs & washers)	$9.90 1'- 2/0 Cable 3"- 3/4" Heatshrink Tube 2 - 2/0 Lugs 2 - Belleville Washers (Confirm hole sizes for lugs & washers)
	For Strap Interconnects: Copper Strap Heatshrink Tube Belleville Washers	$5.50 1'- 1" x 1/16" Strap 9"- 3/4" Heatshrink Tube 2 - Belleville Washers (Confirm hole sizes for washers)	$5.50 1'- 1" x 1/16" Strap 9"- 3/4" Heatshrink Tube 2 - Belleville Washers (Confirm hole sizes for washers)
Automotive Posts (OK To Use)	For Cable Interconnects: Cable Heatshrink Tube Clamps for Battery Posts	$15.40 1'- 2/0 Cable 3"- 3/4" Heatshrink Tube 1 ea. - 2/0 Clamps Positive & Negative	$15.40 1'- 2/0 Cable 3"- 3/4" Heatshrink Tube 1 ea. - 2/0 Clamps Positive & Negative
Automotive Posts (NOT Recommended)	This is the most common post style for flooded lead acid golf cart batteries. However, while they are fine in golf carts, they are NOT recommended for full function vehicles that draw much higher current and attach heavier cables to them. If you get this type of post, DO NOT use the threaded stud as a connection - these will continually loosen until the post melts or starts a fire. Cut off the threaded stud and use the bottom part as if it were an automotive style post.
Dual Purpose "S" Posts (NOT Recommended)	Avoid this post style if possible. It offers reduced contact area for either a clamp style cable end or lugs, and lugs will not bolt up to it well. If you do get this type of post, use it as if it were an automotive style post.

Returns accepted for warranty issues ONLY, for replacement. No cash refunds.
For ordering and warranty information, see the Order Info page.

All info © Electro Automotive 2001-2010