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Author Topic:   Fitting Large Battery Cable to Engine Cowling Bushing
bikingart posted 12-23-2008 07:23 PM ET (US)   Profile for bikingart   Send Email to bikingart  
I will be rigging a battery in a classic Montauk console and plan to use the recommended [2-AWG] wire for the long run. It seems to me that this wire diameter will be too large to fit through the engine cowling opening. Have others run into this? Perhaps the wire needs to be stepped down in size at the transom somehow at a terminal block. I want to avoid a splice.
Casco Bay Outrage posted 12-24-2008 09:04 AM ET (US)     Profile for Casco Bay Outrage  Send Email to Casco Bay Outrage     
Art--When I re-ran my battery cable on my 1987 Montauk to the console, I used [2-AWG] gauge battery cable. Don't confuse [2-AWG] gauge with 2/0, which is really fat.

To get through the 1987 Yamaha 90 engine grommet, I had to remove it and make the two pre-formed holes larger. Don't cut the grommet in place. Too easy to nick a wire or cable.

If this will not work, you could go down in size to a [4-AWG] conductor. Unless you have a large electric load, it will suffice.

Splicing is not a good idea.

jimh posted 12-24-2008 11:20 AM ET (US)     Profile for jimh  Send Email to jimh     
Be sure to get a proper type cable for the new battery cables. You need the very high strand count cable so that it will be sufficiently flexible to bend with the motor.
L H G posted 12-29-2008 10:09 PM ET (US)     Profile for L H G    
The correct way to do it is to use the original engine battery cables, mount a 2 stud HD terminal block/post designed specifically for this purpose on the starboard side of the hull above where a stern installed battery would be, and run the heavier gauge wires from the battery to the same post. No splicing is used, only ring terminals on the end of the cables, and no modification to the engine's original battery cables, other than perhaps some shortening. Be sure the post block has a cover.
L H G posted 12-29-2008 10:19 PM ET (US)     Profile for L H G    
Further to the above, see West Marine cataolg page 419, lower right corner, for "Power Post Single tErminal Connector". You will need two of these @14.99 each, one with 5/16" stud size, and one with 3/8" stud size, or whatever is needed for your original engine cables stud size.
Casco Bay Outrage posted 12-31-2008 01:48 PM ET (US)     Profile for Casco Bay Outrage  Send Email to Casco Bay Outrage     
Larry has a good recommendation.

I have one observation. On my classic Yamaha 90, the OEM cable had a large insulation jacket that was round on one edge but flat on 3 sides. The two cables came attached together and formed a rectangle with curved edges. This mated to the manufactured cutout in the grommet.

The 4 AWG marine battery wire I installed (to eliminate a splice) was slightly wider in overall diameter and did fit in the grommet with just a slight bit of trimming.

I recall the OEM battery wire on my 2003 Yamaha F115 is of the same shape as cited above.

Here is a decent photo of what I am trying to say from Flounder Pounder:

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