Maybe a month ago I bought a Progressive Dynamics converter to replace the OEM in my 2008 Bigfoot. I had a book of Electrician numbers to label the wiring. After removing the wiring I began hooking up the new DC panel/fuse board. The positive battery cable lug on the new board was located a couple inches different than the original. No matter how hard I pulled or manipulated the new board, there was no way I could get the wire on the lug. I got so frustrated I re-installed the OEM. I called the seller, Best Converters, and asked if there was an easy way to add a few inches to that heavy battery cable. They said to use anything, even a wire nut. I asked about a heat shrink butt splice, sure that's fine. Any "best practice" ideas here? Butt splice, crimped on eyes for a bolt and nut? I'm thinking I'd rather not use a wire nut. I'm not sure of the wire gauge, probably about .250".

It's 6 AWG. The average crimpers don't do a good job for me so I usually solder the splice and the lugs and heat shrink anyway. That way no question about the connections.Hardware store probably has a butt splice that will fit if you have the crimpers large enough to do the job.

My 1st thought, as ours is only a few feet from battery, would be replace cable with a longer one. Would also be the least restrictive to its length. A box with stud where you could immobilize both cables. ANL fuse or reset-able breaker would make good 'junction' to add cable. Rated higher than what might be at either end. Last option would be nut & bolting eyes of cables together, I wouldn't, invariably will loosen. If you need to, add extra so you can zip tie the cables together, put in a box.

I would use a butt splice to extend the wire. Preference would be to reposition something or find some slack. Or just pull new wire.http://www.genuinedealz.com/marine-electrical-supply/wire-connectors?cat=170

https://www.amazon.com/Dorman-85261-6-Gauge-Butt-Connector/dp/B00A0FZW7G

https://www.amazon.com/Z-Red-B790C-Hammer-Crimper/dp/B000M7LFKK

Installing Progressive Dynamic converter | Good Sam Community

Joe417
Explorer
Jun 07, 2019
It's 6 AWG.

The average crimpers don't do a good job for me so I usually solder the splice and the lugs and heat shrink anyway.

That way no question about the connections.

Hardware store probably has a butt splice that will fit if you have the crimpers large enough to do the job.
AnEv942
Nomad
Jun 07, 2019
My 1st thought, as ours is only a few feet from battery, would be replace cable with a longer one. Would also be the least restrictive to its length.
A box with stud where you could immobilize both cables.
ANL fuse or reset-able breaker would make good 'junction' to add cable. Rated higher than what might be at either end.
Last option would be nut & bolting eyes of cables together, I wouldn't, invariably will loosen. If you need to, add extra so you can zip tie the cables together, put in a box.
time2roll
Nomad
Jun 07, 2019
I would use a butt splice to extend the wire. Preference would be to reposition something or find some slack. Or just pull new wire.

http://www.genuinedealz.com/marine-electrical-supply/wire-connectors?cat=170
BradW
Explorer II
Jun 07, 2019
https://www.amazon.com/Dorman-85261-6-Gauge-Butt-Connector/dp/B00A0FZW7G
BradW
Explorer II
Jun 07, 2019
https://www.amazon.com/Z-Red-B790C-Hammer-Crimper/dp/B000M7LFKK
Bradymydog
Explorer
Jun 07, 2019
I'm very interested in how you make out as I have the same camper and am considering the same mod.
Chris_Bryant
Explorer II
Jun 07, 2019
Split bolt connectors are bullet proof-
midnightsadie
Explorer II
Jun 07, 2019
some good advice,me I,d run a new cable.
ppine
Explorer II
Jun 07, 2019
A new cable should be easy.
Kayteg1
Explorer II
Jun 07, 2019
In Europe wire nuts and butt connectors are unknown.
They use screw connectors everywhere.
Work well on US circuit breakers.