ausmini :: View topic - Jumper Leads

Those are all crap really, but the bigger the better.
I'd like to see the voltage drop when they are passing their rated current.
:lol:

A starter will pull over 200A when cranking, and you want minimal voltage drop.

I make my own, from 24mm² welding cable and 300A earth clamps... cost me about $75 for a 3M set.

I buy my cable from industrial welding supply shops.
You need:
4 earth clamps, 300A min
4 cable lugs, for 24mm2 cable
6M (or whatever) of 24mm² welding cable (yes bigger is better but 24mm² is HUGE compared to normal `jumper leads'). This will give you a lead set 3M long which is fine for most use. (Ask Mini_Mad how it works, he has a set)

I solder the lugs to the cables with a 600C hot air gun and rosin cored solder. A propane gas torch works fine too. Watch you don't burn the cable coating.Forget a soldering iron for lugs this big.

When cooled, whip some PVC tape around the cable ends to finish them off.

Then I paint 2 clamps red, and the other 2 black.

Would it be worth looking at a 4wd supply shop?

I tend to find when it comes to stuff like that there's usually better quality stuff available if you're willing to pay for it from the hard core shops...

OFC Ultra High Current Power cable

Run from your battery to distribution blocks and then 2GA, 4GA or 8GA to your amplifiers or other power equipment for seriously high current applications.

• Conductor material: OFC
• Stranding: 7 x 7 x 81 / 0.12mm
• Current capacity: 200A
• Insulation material: PVC
• Total diameter: 15mm
• Resistance @ 20°C: 350 micro ohms/m
• Roll length: 25m
• Sold per metre

Red 0GA cable Cat No. WH-3092
Black 0GA cable Cat No. WH-3094

MOWOG, that lead says

Quote:

Does that mean it's 200amps, the same as the cheapie ones from Supercrap?

Those are all crap really, but the bigger the better.
I'd like to see the voltage drop when they are passing their rated current.
:lol:

A starter will pull over 200A when cranking, and you want minimal voltage drop.

I make my own, from 24mm² welding cable and 300A earth clamps... cost me about $75 for a 3M set.

Cable & Hoses; Oxy, Acet, LPG & Argon hoses, Air line hose 6mm & 10mm, Cables from 25mm, 35mm, 50mm & 70mm.

Author:	Danny [ Sat Feb 06, 2010 10:30 am ]
Post subject:	Jumper Leads
I'm going out today to buy some jumper leads, but I'm not quite sure what to get. Supercrap has a hole lot of different leads, from - 100amp leads for $23 - 200amp leads for $28 - 400amp leads for $43 - 750amp leads for $73. What is the difference, and what am I best getting? I'm not going to be jumpstarting a prime mover, just things mini sized up to 4wd sized I suppose. Cheers

Author:	drmini in aust [ Sat Feb 06, 2010 10:33 am ]
Post subject:
Those are all crap really, but the bigger the better. I'd like to see the voltage drop when they are passing their rated current. A starter will pull over 200A when cranking, and you want minimal voltage drop. I make my own, from 24mm² welding cable and 300A earth clamps... cost me about $75 for a 3M set.

Author:	Danny [ Sat Feb 06, 2010 10:46 am ]
Post subject:
drmini in aust wrote: Those are all crap really, but the bigger the better. I'd like to see the voltage drop when they are passing their rated current. A starter will pull over 200A when cranking, and you want minimal voltage drop. I make my own, from 24mm² welding cable and 300A earth clamps... cost me about $75 for a 3M set. Everyone seems to say to make your own, but I wouldn't know how. Where do you get your welding cable and clamps from? How do you attach the wire from the cable to the clamps?

Author:	Mick [ Sat Feb 06, 2010 10:49 am ]
Post subject:
Doc's spot on as always. Bigger is always better....but this is a relative matter when it comes to anything involving copper conductors from supercheap repco or autobarn. If you really want fine cables, then 70sqmm flexible cable terminated with utilux crimps bolted to your clamps make for heirloom quality cables...the type you would want your granddad to pass down to you... Cable can be had from places like Ideal, clipsal, Laurance and Hanson (L&H). Same with the crimps. Welding supplies have earth clamps which are real quality.

Author:	Mick [ Sat Feb 06, 2010 10:53 am ]
Post subject:
I say 70 sqmm because 90 sqmm is rated for 100 Amps continuous, but you will only use it for a few minutes which is perfect. You can start a car which hasn't even got a battery fitted to it with this size of cable. As you go down then voltage drop increases at full load which reduces starter torque by the square of the difference. They don't get that much larger for the jumps in size either. You're always going to be limited by the contact area of the clamps, always try to maximise the amount of clamp you have contacting the metal posts, even with cheap sets.

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Jumper Leads https://www.ausmini.com/forums/viewtopic.php?f=2&t=60890	Page 1 of 2

Author:	drmini in aust [ Sat Feb 06, 2010 11:05 am ]
Post subject:
I buy my cable from industrial welding supply shops. You need: 4 earth clamps, 300A min 4 cable lugs, for 24mm2 cable 6M (or whatever) of 24mm² welding cable (yes bigger is better but 24mm² is HUGE compared to normal `jumper leads'). This will give you a lead set 3M long which is fine for most use. (Ask Mini_Mad how it works, he has a set) I solder the lugs to the cables with a 600C hot air gun and rosin cored solder. A propane gas torch works fine too. Watch you don't burn the cable coating.Forget a soldering iron for lugs this big. When cooled, whip some PVC tape around the cable ends to finish them off. Then I paint 2 clamps red, and the other 2 black.

Author:	Danny [ Sat Feb 06, 2010 11:08 am ]
Post subject:
drmini in aust wrote: I buy my cable from industrial welding supply shops. You need: 4 earth clamps, 300A min 4 cable lugs, for 24mm2 cable 6M (or whatever) of 24mm² welding cable (yes bigger is better but 24mm² is HUGE compared to normal `jumper leads'). This will give you a lead set 3M long which is fine for most use. (Ask Mini_Mad how it works, he has a set) I solder the lugs to the cables with a 600C hot air gun and rosin cored solder. A propane gas torch works fine too. Watch you don't burn the cable coating.Forget a soldering iron for lugs this big. When cooled, whip some PVC tape around the cable ends to finish them off. Then I paint 2 clamps red, and the other 2 black. How long do they take to make and how much do they weigh? Are you interested in making me a set if I pay for materials, postage, and beer money Doc?

Author:	GT mowog [ Sat Feb 06, 2010 11:32 am ]
Post subject:
Making your own you'll end up with an expensive but good quality set, you want to be able to depend on them when you need them. I have found that the cheap sets can be OK if you solder the connections, they are only crimped and are really poor. 100 or 200 amp should do it OK for a Mini. The bigger sets get bulkier to store, which is where they are most of the time.

Author:	woodwormm [ Sat Feb 06, 2010 11:34 am ]
Post subject:
Would it be worth looking at a 4wd supply shop? I tend to find when it comes to stuff like that there's usually better quality stuff available if you're willing to pay for it from the hard core shops...

Author:	GT mowog [ Sat Feb 06, 2010 11:40 am ]
Post subject:
woodwormm wrote: Would it be worth looking at a 4wd supply shop? I tend to find when it comes to stuff like that there's usually better quality stuff available if you're willing to pay for it from the hard core shops... Possibly worth trying. Have a good look at the clamps, usually this is where they try to save money and I'think you'll find most manufactured sets have crimped in cables which is what will let them down.

Author:	GT mowog [ Sat Feb 06, 2010 11:48 am ]
Post subject:
Jaycar have all the stuff you need;- Red Cable http://www1.jaycar.com.au/productView.a ... BCATID=491 Black Cable http://www1.jaycar.com.au/productView.a ... BCATID=491 Clips http://www1.jaycar.com.au/productView.a ... BCATID=516 Don't be tempted to make them too long, the voltage drop will make them less effective.

Author:	Danny [ Sat Feb 06, 2010 11:58 am ]
Post subject:
MOWOG, that lead says Quote: OFC Ultra High Current Power cable Run from your battery to distribution blocks and then 2GA, 4GA or 8GA to your amplifiers or other power equipment for seriously high current applications. • Conductor material: OFC • Stranding: 7 x 7 x 81 / 0.12mm • Current capacity: 200A • Insulation material: PVC • Total diameter: 15mm • Resistance @ 20°C: 350 micro ohms/m • Roll length: 25m • Sold per metre Red 0GA cable Cat No. WH-3092 Black 0GA cable Cat No. WH-3094 Does that mean it's 200amps, the same as the cheapie ones from Supercrap?

Author:	GT mowog [ Sat Feb 06, 2010 12:03 pm ]
Post subject:
Danny wrote: MOWOG, that lead says Quote: OFC Ultra High Current Power cable Run from your battery to distribution blocks and then 2GA, 4GA or 8GA to your amplifiers or other power equipment for seriously high current applications. • Conductor material: OFC • Stranding: 7 x 7 x 81 / 0.12mm • Current capacity: 200A • Insulation material: PVC • Total diameter: 15mm • Resistance @ 20°C: 350 micro ohms/m • Roll length: 25m • Sold per metre Red 0GA cable cat No. WH-3092 Black 0GA cable cat No. WH-3094 Does that mean it's 200amps, the same as the cheapie ones from Supercrap? You'll find it better than those, the stuff from jaycar is OFC which means it is a lower resistance (less voltage drop) than the stuff from supercrap. And the clips are infinitely better. <EDIT> It has a 200 amp contiuous rating, so for jump starting, they'll do 400 Amps+ (Short Time Rating)

Author:	Morris 1100 [ Sat Feb 06, 2010 12:18 pm ]
Post subject:
If you have a good auto electrician nearby you might be able to get him to solder the ends onto the cable according to DrMinis directions.

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Author:	Danny [ Sat Feb 06, 2010 12:26 pm ]
Post subject:
drmini in aust wrote: Those are all crap really, but the bigger the better. I'd like to see the voltage drop when they are passing their rated current. A starter will pull over 200A when cranking, and you want minimal voltage drop. I make my own, from 24mm² welding cable and 300A earth clamps... cost me about $75 for a 3M set. So I've been googling, and Toowoomba Welding Supplies sells Quote: Cable & Hoses; Oxy, Acet, LPG & Argon hoses, Air line hose 6mm & 10mm, Cables from 25mm, 35mm, 50mm & 70mm. .........I take it that you've got the 25mm cable Doc? If I buy the cable from there, would the Jaycar clips that MOWOG posted be ok? Or should I look for something more heavy duty? Is joining them up something that a auto electrician should do? My father in law is a boilermaker, so would he be able to join them? Weld them??