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Old 08-16-2021, 07:50 PM   #1
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Exclamation Dinghy Wire gauge for battery terminal?

Hi folks,

I have had to put new lugs on my dinghy battery whilst away on Pender Island. The local marine store was hopeless, and the hardware store only has car size copper lugs which are too large, but have worked in a pinch as a temporary fix. Does anyone know what size lugs I should order and battery terminal ring size for this? It's a 20hp Tohatsu engine fitted with a 12v battery, and the copper wire diameter looks just over 4mm inside the insulation. See attached pics. Any suggestion which size lugs and ring size I should order? Luckily I have a good crimper that came with the boat. I was thinking they look like 6 AWG?

Any tips gratefully received!
Cheers
Bill
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Old 08-17-2021, 07:24 AM   #2
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Just measure the battery terminals. Sometimes they are two different sizes.

The wire gauge should be printed on the insulation of the wire.

As for crimping, it's very important to use the correct size crimper. #6 is pretty rare for a crimper.

Some marine stores will let you use a crimper if you buy your lugs there. Ask.
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Old 08-18-2021, 10:48 AM   #3
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Wire gauge query

Unfortunately it doesn't I am afraid as there is no size printed on the wire. Just says SEIWA.
Bill
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Old 08-18-2021, 11:27 AM   #4
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3, 4, and 5 mm DIA equate roughly to #8, 6, and AWG 4.
My metric calipers is what i would use on a stripped free end.
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Old 08-18-2021, 04:24 PM   #5
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Wire gauge query

Perfect. It looks like a 6 AWG and I can estimate the ring size.
The crimpers I have do 6 lugs, but looks like that will be a tight squeeze!

Thanks
Bill
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Old 08-19-2021, 05:46 AM   #6
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I'd be sure to use good quality tinned power (not starter) terminals.
There is a big difference between the smaller, lighter, open end untinned variety and the real deal.
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