Battery Cables
Custom made battery cables feature pure copper conductors with copper connectors such as ring terminal cable lugs and top post style battery terminals. We offer many sizes and configurations of battery cables which you can custom design here on the site. The battery cables are organized by wire gauge size below. If you don't see a cable style you need please email or call us and we'd be glad to help design the cable for you.
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Always start by looking on the side of the wire for printing that should tell you the wire size. Sometimes there is a stamp in the connector which indicates the size as well. Different styles of stranding in the cable as well as various insulation thicknesses mean there is not a "one size fits all" exact measurement but here are measurements based on a range of typical battery cable styles as a reference. (when in doubt between wire sizes ALWAYS choose the larger wire size)
| Wire Gauge Size | COPPER CONDUCTOR Diameter (no insulation) | Overall Outside Diameter with Insulation |
| 8 | 0.143-0.165 inch (3.63-4.19 mm) | 0.218-0.270 inch (5.54-6.86 mm) |
| 6 | 0.181-0.200 inch (4.60-5.08 mm) | 0.305-0.340 inch (7.75-8.64 mm) |
| 4 | 0.219-0.252 inch (5.56-6.40 mm) | 0.343-0.405 inch (8.71-10.29 mm) |
| 2 | 0.289-0.326 inch (7.34-8.28 mm) | 0.418-0.475 inch (10.62-12.07 mm) |
| 1 | 0.341-0.361 inch (8.66-9.17 mm) | 0.479-0.520 inch (12.17-13.21 mm) |
| 1/0 (0) | 0.348-0.405 inch (8.84-10.29 mm) | 0.500-0.565 inch (12.70-14.35 mm) |
| 2/0 (00) | 0.429-0.460 inch (10.90-11.68mm) | 0.568-0.655 inch (14.43-16.64 mm) |
| 3/0 (000) | 0.485-0.510 inch (12.32-12.95mm) | 0.641-0.670 inch (16.28-17.02 mm) |
| 4/0 (0000) | 0.555-0.580 inch (14.10-14.73mm) | 0.695-0.741 inch (17.65-18.82 mm) |
Yes, we have a cable identification table in Question #7 above which can help you figure what size cable you currently have however you might need additional information in order to calculate the correct wire size to use and a voltage drop calculator is a great tool...click here to use the voltage drop calculator