Extending 6 Gauge Wire - Best Practices?
 

The ground wire on the Andersen connector is too short. I can't get it reach our breaker panel, and without the need for a ground stud like last year's multiple breakout setup, I want to avoid using one.

What are the best practices in extending the 6 gauge wires on the Andersen connectors? Splice? Bolt two lugs together, and wrap in electrical tape? Break down and make space to mount a ground stud for just two wires?

How do you do it?

-SlimBoJones...

Re: Extending 6 Gauge Wire - Best Practices?
 

Why not replace the entire wire with one long enough for your needs?

Re: Extending 6 Gauge Wire - Best Practices?
 

We usually pull the wires out of the Anderson connector, use pliers to remove the tab things, and re-crimp, solder, and heat-shrink tube them onto longer and more flexible 4 AWG wire. We never have problems with them after this.

Re: Extending 6 Gauge Wire - Best Practices?
 

This, and the one above, is the best method. However there are crimping blocks that can be used, just make sure you buy one that can handle two #6 cables. Split bolt connectors such as McMaster Carr #6921K57 is an example. Wrap it well with insulating tape!

Re: Extending 6 Gauge Wire - Best Practices?
 

Thanks all!

Appreciate the solution(s)!

Re: Extending 6 Gauge Wire - Best Practices?
 

I know this isn't probably the best method (the 4awg method sounds a lot better in fact...) but in a spot last year we were getting the bot ready for a presentation to get a sponsor, and it turned out that a splice in one of the 6awg, was just 2 battery lugs bolted together, and one of the lugs was coming loose.

Well I decided that soldering it was probably the best solution right then. So I pulled the battery lugs off (rather easily I might add :-/ ) spread the wire out a bit, meshed the two pieces together, and soldered the joint with a propane torch (a full sized one not a mini one, big ol 12" flame on that sucker)

For last minute work it came out nice, I would be more confident in that than the battery lugs. For some reason I have an immense disliking for non-soldered joints. Maybe it is just all the hobby electronics I do...

Re: Extending 6 Gauge Wire - Best Practices?
 

just as long as you know how to solder (ex) dont use a puny 20W iron for 6 guage), it might not be as efficient or flexible but it will be solid

Re: Extending 6 Gauge Wire - Best Practices?
 

We bought identical connectors to the ones in the kit and are soldering in 6 ga welding cable (super flexible and finely stranded) It was a pain to find (in red). We would have gone to 4 ga (and bigger powerpoles) but the 50 amp SB powerpoles (which we are required to use) only support contacts for up to 6 ga, so high quality 6 ga it is. :)