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Old 07-29-2009, 09:29 PM   #7 (permalink)
ProX
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Join Date: Feb 2009
Location: Iowa

Besides conductor gauge, a wire is rated on it's ability to handle and disperse heat. This is done through it's insulation.

8 gauge wire with a insulation rated at 90*C (ex. THHN or THHW) is good for 80amps in free air or 55 amps in conduit or another form of raceway.

If you step up to a higher temp rated insulation, like a 150*C rated wire, you'll be good for 106 amps or 124 for 200*C wire. (both specs are free air)

#6 is good for 75 in conduit, 80 in free air when using a 90*C insulation.

150*C insulated wire will handle 155amps in free air, and 200*C wire will handle 165 in free air.

Go to the welding supply store (farm stores too) and look for your desired gauge in welding cable. Outstanding insulation and a fine stranded conductor. MAKE SURE WHATEVER END YOU USE ARE PROPERLY SECURED!!! If using a crimp on end, buy or rent the proper crimper, not the typical auto parts store multi-tool junk. If you want more info on them, let me know. A good alernative is to solder and shrink wrap them.

I use welding cable for all my battery cables and as an added bonus, it's usually WAY cheaper than wire from the parts or hardware store.
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