How to Measure Custom Cables

The following is intended to give you a guide on how to measure your custom-built power cables:

Unit of Measure:

We measure in metres with 0.01m (1cm or 10mm) increments so we can be more precise with our tolerances.
Our system accommodates decimals, so you can measure to the nearest centimetre (0.01m or 10mm)
For example 750mm or 75cm will need to be entered as 0.75m.

 

Measuring Replacement Cables:

Remove cable and re-shape it as straight/long as possible (make allowances in length if not completely straight)
Measure from centre of terminal to centre of terminal of existing cable
When measuring from centre to centre make sure to allow 15-25mm each end to accommodate the terminals extending from the cable. This can reduce the actual cable length needed by approximately 50mm.
This can vary depending on the size of the cable and associated terminals. (Refer below examples)
Where possible, it is good practice to measure the cable slightly longer

 

Example:

Your existing 000B&S cable measures 60m (60cm or 600mm) lug centre to lug centre.
Reduce the length by 25mm per 95mm lug
The actual cable length will need to be cut at 55m (55cm or 550mm).
600mm - (2 x 25mm) = 550mm. This would entered as 0.55m in our cable customiser.

New Cables:

A good tip for measuring new cables is to use a hose or rope to mimic the length of cable required. Mark or tape at the required terminal locations.
Allow extra length for any bends or curves
Allow for areas that may require extra clearance (exhaust, etc.)
When measuring from centre to centre make sure to allow 15-25mm each end to accommodate the terminals extending from the cable. This can reduce the actual cable length needed by approximately 50mm.
Where possible, it is good practice to measure the cable slightly longer

 

Twin Sheath Cables

We cut both cores (red & black) to the same length
The outer sheath will be trimmed to the minimum requirement to crimp ends depending on cable & terminal sizing (you can easily trim more later to suit your specifications or leave us a note in the cart)

 

Added Heat Shrink

We use 50mm of your choice of standard or adhesive-lined dual wall heat shrink per termination
Heat shrink is not essential on Anderson Connectors or Booster Clamps

 

Added Sleeving

Single Core

• Any sleeving added to single core cables will cover the entire length of the cable insulation.
• You can easily trim more later to suit your specifications or leave us a note in the cart.

Twin Core

• Any sleeving added to twin core cables will cover the entire length of the outer insulation which is trimmed to the minimum requirement to crimp ends depending on cable & terminal sizing
• You can easily trim more later to suit your specifications or leave us a note in the cart.

 

Tolerances

• We build in a tolerance to all our custom-built cables.
• The shorter the cable, the tighter the tolerance will be.
• Cables will always be made slightly longer than specified (refer below).

 

Cables Under 0.3m (300mm)

• These cables will have a tolerance of 0-10mm longer than ordered

 

Custom Cables 0.3m – 2m (300mm – 2000mm)

• These cables could have a tolerance of 10-20mm longer than ordered

 

Extra Long Cables Over 2m (2000mm)

• These cables could have a tolerance of 20-40mm longer than ordered

 

Please note: As these are custom made cables, any cable that has been made to your specification but ends up being short will not be refunded. Make sure to double check your measurements.

If you are still unsure of your measurements please contact us via email

sales@custompowercables.com.au