1960s 1968 Battery cable size

[robert G. smits]

A friends recently purchased 68 appears to have very small battery cables about half the size of my 58 and has symptoms of voltage drop when starting. Does anyone know the correct gage and is there a source of replacement or should we simply make them?  Thanks Bob Smits #2426

[Big Fins]

If you have the ways and means to make your own correctly, I would use '00' welding cable, soldering and crimping the ends on. Wire wheel any frame connections of the cables and the starter. Also starter to frame ground strap connections. And do both cables, not just one.

[Mike Baillargeon #15848]

If you don't do your own cables, these guys do a great job.

https://www.batterycablesusa.com/00-gauge-2-0-awg-marine-grade-battery-cable-with-ends

You tell them what color, what ends you want, what length you need and what size cable you want.....

Quick turn around and reasonably priced....

Mike

[David Greenburg]

I definitely second going big on the cables. I had 00 cables made up for my '60 from the Pacer Group. They are primarily a supplier to manufacturers, but they do custom retail work. Not sure how they stack up price-wise with Mike's recommendation, but I remember thinking the price was very reasonable at the time.

[TJ Hopland]

Parts store cables have always been a little on the small side and even worse if you look at the copper to insulation ratio. And that was before copper got really expensive and copper plated iron wire was a thing like it is now.

Semi custom cables from a legit place that specializes in such things or repro cables from a long standing vendor if that is your style.   For sure no online specials or regular off the rack parts store ones.  I have a regional farm and fleet sort of place I have been getting cables at when a big fat top post cable will work.   

[Warren Rauch #4286]

       Oversize cables should help the voltage drop when starting.
 
      The 1968 shop manual calls for 2 gage cables.  The 1958 shop manual for 4 gage cables. Since gage numbers go down as size goes up, the 68 should be bigger than than the 58.

   Warren

[robert G. smits]

Thanks to all who replied and for the info on reliable vendors. It wouldn't surprise me if the current cables are 6 or smaller.

[bcroe]

If the cables are very short and well terminated,
smaller conductors will work.  Basically they are
overloaded but for too short a time to damage.
Extended cranking might do damage.  You may see
the same thing on the alternator output, which
only see a peak right after cranking the engine,
not continuously.  I have been meaning to upgrade
mine.  Bruce Roe