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Extending Battery Cables
I am in the process of replacing the battery pack and other components in my Escort EV; the cables that were run from back to front for the original set-up are too short to reach where the new post connections will be. I also have to change the connectors from automotive to lug end. The original company did a good job of pulling all the cables together through 2" PVC conduit, and they are a very snug fit; I can't tell if they strapped all of the cables together or not, which makes pulling out the 2/0 cable and pulling new cables through (which would be my first choice) very difficult if not impossible. I have used heavy copper bus bars in the past on other EV's as connectors between lug ends on 2/0 cable in some places.
Is there a better way to extend cables? I wouldn't think that a crimped butt splice connector would be anywhere near capable of safely passing full pack amperage for an EV. In low voltage (36 & 48 volt) EV's. I have just bolted the lug ends together without ever seeing problems, but it doesn't seem like it would be sufficient for this application.
What would be the best way(s) to do this?
Thanks!
Michael B
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