Battery Relocation Wire Manufacturer —— High-Performance Battery Modification Cable Solutions
Battery relocation wires are key to achieving stable power supply and safe connections. As a professional wire harness manufacturer, Linkwings offers custom battery relocation wire solutions in multiple specifications, with high flexibility and high current resistance.
Custom Battery Relocation Wire from Wire Harness Manufacturer
In projects such as battery relocation modifications, RV dual-battery systems, and high-performance audio power supply applications, standard cables often fail to meet the comprehensive requirements of long distances, high currents, high temperatures, and high flexibility. As a professional wire harness manufacturer, Linkwings offers Custom Battery Relocation Wire solutions. From conductor wire gauge, jacket material, to terminal type and protection rating, all components can be customized to your installation environment and electrical parameters, ensuring stable power supply and reliable safety.
Linkwings employs advanced conductor stranding, terminal crimping, and protective encapsulation processes. All custom battery relocation wires undergo 100% electrical and mechanical performance testing and comply with international standards such as UL, RoHS, and ISO. We not only provide high-performance cable products but also offer engineering-based wiring recommendations and installation accessory support to ensure your battery relocation project is completed efficiently and operates reliably over the long term.
battery relocation wire Types
In various battery relocation and power rewiring projects, the type and structure of battery relocation wires directly affect system safety and power supply efficiency. Linkwings offers a wide range of products with different specifications and functionalities to meet the diverse needs of racing cars, motorhomes, modified vehicles, and industrial equipment.
Battery Power Feed Wires
Function: Responsible for transmitting positive battery current to the starter motor, fuse box, or main power distribution point
Product Features:
- Made with high-purity multi-strand bare copper or tin-plated copper conductors to ensure low resistance and high conductivity
- Supports multiple wire gauges from 4 AWG to 1/0 AWG, suitable for high-current loads
- Sheath materials available in PVC, XLPE, or TPE, offering high-temperature resistance and wear resistance
Battery Ground Wires
Function: Establish a stable negative circuit to reduce system noise and voltage fluctuations.
Product Features:
- Highly flexible conductor for easy wiring in confined spaces.
- Optional multi-point grounding design for enhanced system electrical stability.
- Corrosion-resistant tin-plated copper conductor for extended service life.
Starter/Kill Switch Harness
Function: Connects the battery to the starter circuit and can be integrated with a kill switch function.
Product Features:
- Pre-installed with high-quality copper terminals and protective heat shrink tubing.
- Optional quick kill switch module, suitable for racing and high safety requirement modification projects.
- Supports IP67 waterproof design, highly durable for outdoor use.
Battery Distribution/Split Kits
Function: Distributes main power to multiple devices (such as lighting, audio, and control systems)
Product Features:
- Modular structure for quick installation and maintenance
- Integrated cable and distribution module design reduces the number of connectors and improves reliability
- Optional fuse protection prevents damage from branch circuit short circuits
Pre-terminated Custom Assemblies
Function: Plug-and-play battery connection cable, saving installation time
Product features:
- Terminal crimping, resistance testing, and insulation testing completed before leaving the factory
- Terminal crimping is secure, with additional heat-shrink sleeve protection
- Supports color coding and label identification for convenient wiring management
Technical Specifications & Datasheet
| Parameter | Specification |
|---|---|
| Wire Gauge (AWG) | 4 AWG ~ 1/0 AWG (customizable) |
| Conductor Material | High-purity stranded bare copper / tinned copper, low resistivity (≤0.0172 Ω·mm²/m) |
| Rated Voltage | 600V / 1000V (depending on application) |
| Rated Current | Up to 150A ~ 300A (depends on gauge and temperature rise) |
| Operating Temperature | -40°C ~ +125°C (up to 150°C with XLPE jacket) |
| Jacket Material | PVC (economic), XLPE (high-temp), TPE (oil & abrasion resistant) |
| Insulation Color | Red, Black, Blue (custom color coding available) |
| Termination Options | Copper lugs, ring terminals, Anderson connectors, etc. |
| Protection Rating | IP65 / IP67 (optional waterproof sealing) |
| Testing Standards | 100% continuity test, hipot test, tensile strength test |
| Certifications | UL, RoHS, REACH, ISO9001 (optional) |
Why Use battery relocation wire？
In applications such as race car modifications, RV wiring, high-power audio systems, or special power engineering projects, battery relocation wire serves not only as a physical connection but also as a critical component ensuring the stability and safety of the power supply system. Compared to standard cables, specialized battery relocation wire offers the following advantages:
- High current-carrying capacity: Utilizes large-gauge, multi-strand, high-purity copper conductors (e.g., 4 AWG, 2 AWG, 1/0 AWG). Low resistance and minimal heat generation, enabling stable current handling of 150A to 300A.
- High flexibility for easy routing: The stranded conductor design and flexible jacket construction allow the cable to easily navigate tight spaces or vehicle structures, enabling flexible installation and reducing the risk of breakage.
- High-temperature and wear resistance: Jackets made from materials like XLPE and TPE maintain performance in temperatures ranging from -40°C to 125°C and offer resistance to oil, corrosion, and UV radiation.
- Enhances overall vehicle electrical system performance: By reducing high-voltage drop paths and minimizing electromagnetic interference, it improves startup efficiency, audio performance, and overall power stability.
- Customizable to meet special requirements: Supports custom lengths, colors, connector types, and waterproof packaging.
Linkwings battery relocation wire Solutions
Case 1: Racing Car Battery Rear Relocation Modification Project
Modification Project Customer Background: A professional racing car modification factory needed to relocate the vehicle battery to the trunk to optimize front-to-rear weight distribution and free up engine compartment space.
Project Challenges:
- High current instantaneous start-up requirements (>250A)
- High temperatures and frequent vibrations in the track environment
- Narrow installation path and need to avoid electromagnetic interference
Linkwings Solution:
- Utilizes 1/0 AWG high-flexibility tin-plated copper conductors to ensure low impedance and stable power supply
- XLPE high-temperature jacket (temperature-resistant up to 150°C), vibration-resistant and abrasion-resistant
- Customized copper lug terminals with heat-shrink packaging, paired with a quick-disconnect switch module
- Optimized routing design to minimize 90° sharp bends, ensuring stable signal and power transmission
Case 2: RV Dual Battery System Wiring
Customer Background: North American RV manufacturer plans to install a dual battery system in RVs to separate living power from starting power.
Project Challenges:
- Long-distance power supply with high voltage drop control requirements
- Outdoor use requires waterproofing and UV resistance
- Wiring must pass through the chassis to prevent wear and corrosion
Linkwings Solution:
- Utilizes 2 AWG tinned copper multi-strand conductors to reduce resistance in long-distance power supply
- Sheath made of TPE material, oil-resistant, waterproof (IP67), and UV-resistant
- Installs corrugated tubing and abrasion-resistant sleeves to protect wiring in the chassis section
- Provides red and black color-coding for easy identification of positive and negative terminals and future maintenance
Case 3: High-Performance Audio System Battery Relocation
Customer Background: A car audio modification shop needed to install a trunk audio power supply for a customer, requiring the battery to be relocated to the rear to reduce engine compartment congestion.
Project Challenges:
- The audio system requires stable high-power supply (>200A)
- Prevent low-frequency noise and voltage fluctuations
- Wiring must be concealed and aesthetically pleasing
Linkwings Solution:
- Use 4 AWG high-purity bare copper wire to ensure stable high-power output
- Shielded structure design to reduce electromagnetic interference (EMI)
- Black high-flexibility PVC jacket, compatible with in-car concealed wiring solutions
- Provide custom lengths and pre-crimped terminals for plug-and-play installation, saving installation time
FAQs about battery relocation wire
Q1: How do I choose the appropriate battery relocation wire gauge?
A1: The selection of wire gauge (AWG) depends on the system’s rated current, line length, and allowable voltage drop. Generally, 4 AWG is suitable for currents below 150A and short-distance wiring; 2 AWG is suitable for 200A-level applications; and 1/0 AWG can handle currents above 250A. Linkwings can perform electrical calculations based on your specific application and recommend the optimal wire gauge.
Q2: Does the battery relocation cable require special insulation?
A2: Yes. Depending on the installation location and operating environment, the insulation material must have high-temperature resistance, wear resistance, oil resistance, and UV protection. For example, in engine compartments or undercarriages, XLPE or TPE insulation is recommended to enhance safety and longevity.
Q3: What should be noted when installing the battery relocation wire?
A3: Ensure the cable path avoids sharp bends and high-friction points; use corrugated tubing or protective sleeves as needed. Terminals must be securely crimped and sealed with heat-shrink tubing to prevent oxidation and loosening. For racing or long-distance wiring, we also recommend installing a quick-disconnect switch and fuse protection.
Q4: How can system stability be improved after battery relocation?
A4: Selecting low-resistance, large-cross-section conductors and optimizing wiring paths can effectively reduce voltage drop and heat generation. Additionally, adding extra grounding wires and using shielded cable structures can minimize electromagnetic interference, ensuring startup efficiency and the stability of audio and control systems.