Battery Cables

Making a custom length battery cable takes a drill, mini-torch, crimper dies, flux, and solder.

We do lots of custom electrical work in the fab shop, and one job that seems to come up all the time is making custom battery cables. Trying to find ready-made cables that are exactly the right length is difficult at best, and damn near impossible for those extra-long cables when your battery has been moved to the trunk. Given the weight and cost of heavy gage copper cables  we make our own, using SAE-rated battery cable, and heavy-duty cable lugs to get exactly the right length.
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PTFE Hose and Fittings

There’s no ferrule in this hose end. The collar slides over the hose, and the fitting threads directly into the PTFE liner. It’s lightweight and easy to do, and no bleeding required.

We’ve gotten a lot of requests for more information about the hose we used in our twin vent install on the Tommy Camaro. It uses a PTFE inner liner, which is important to reduce fuel permeation (smell), and an Aramid outer braid. Aramid is a Kevlar brand name and it is tough stuff. It is literally bullet-proof. The braid feels soft to the touch, but requires side-cutters to cut the thread — it just laughs off heavy duty scissors.

Assembly is easy: just slid the outer (silver) collar over the end of the hose, and then twist the fitting (black) into the hose with some light lubricant. The fitting twists easily into place with your hand or a short AN wrench, and the fine threads on the inner fitting support easy clocking for non-straight hose ends. The hose is rated for high-pressure applications, including power steering. You can get all of it at Pegasus Racing.

I’ve also gotten several requests for the part numbers we used in the install, so here they all are in one place:

  • Vent fitting: 90 degree AN ORB fitting is an Earl’s part: AT949006ERL
  • Tank fitting: 90 degree 1/4 NPT to AN 6 is also Earl’s: AT982206ERL
  • Vent hose end: 90 degree AN 6 Pegasus Racing hose end: 3481-06-90 DEGREE
  • Tank hose end: straight AN 6 Pegasus Racing hose end: 3481-06-STRAIGHT
  • Hose: Aramid braided (Kevlar… and it will take its toll on your cutting tools) AN 6 PTFE hose from Pegasus racing. 3490-06-FOOT

FabBosses used to secure ECM

The GM E67 ECM is securely mounted with 4 FabBosses

Progress continues on the 69 Camaro. We’re working on wiring the car and adapting the GMPP harness to manage our LS3. Using FabBosses to mount the ECM was easy. We bolted a 1/4 – 20 versions to the ECM, trimmed them slightly to deal with the curvature of the panel, and welded them in place. It wasn’t necessary to fully weld the FabBosses — we just put two solid 1/2″ welds on each side of the ‘Boss. Total time: 1 hour.

Unfair electronics device tray done

Welded Fab Boss

The device tray is fully mounted, taking 9 FabBosses — 2 on each side and one in the middle. Only the one in the middle took any real careful measuring — and that was because I couldn’t get my MIG gun all the way underneath the tray. All the other FabBosses were bolted to the tray, trimmed to fit, and tack-welded into place. Continue reading