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 centimetres (not metres or inches) so we can be more precise with our tolerances.
Our system does not accommodate decimals, so you will need to measure to the nearest centimetre
Measuring Replacement Cables:
Remove cable and re-shape it as straight/long as possible (make allowances in length if the cable is 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 approx 1.5-2.5cm each end to accommodate the terminals extending from the cable.
This can reduce the actual cable length needed by approximately 5cm.
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
60cm lug centre to lug centre.
Reduce the length by
2.5cm per 95mm² lug
The actual cable length will need to be cut at
55cm.
60cm - (2 x 2.5cm) = 55cm
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 approx 1.5-2.5cm each end to accommodate the terminals extending from the cable.
This can reduce the actual cable length needed by approximately 5cm.
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 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.
Heat Shrink
We use 5cm of adhesive lined dual wall heat shrink per termination
Heat shrink is not required on Anderson Connectors or Booster Clamps
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 30cm
These cables will have a tolerance of 0-1cm longer than ordered
Custom Cables 30cm - 200cm
These cables could have a tolerance of 1-2cm longer than ordered
Extra Long Cables Over 200cm (2m)
These cables could have a tolerance of 2-4cm 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.
