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Replacing copper bar with tefzel wire

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jcohen@post.com

Joined: 10 Mar 2022
Posts: 17

Posted: Fri Feb 03, 2023 7:47 pm Post subject: Replacing copper bar with tefzel wire

I am building a Vans RV7 , IO360, Z101, using B&C master and starter contactors, and an EarthX ETX 900 battery. I can’t easily use the Vans design solution of 0.125” thick copper bar, about 3” long x 0.5” wide, to connect the master solenoid to the starter solenoid, due to physical placement on my firewall and the stud orientation on the B&C starter contactor. So I want to use an insulated wire instead of the bar, maybe only 4” or so. 



From old posts on vansAirforce.net forum, the current here is estimated to be up to 320 amps for short periods while cranking the starter. Is that correct? What gauge tefzel wire should I use to maintain the functionality and safety of the copper bar?

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Jeff

user9253

Joined: 28 Mar 2008
Posts: 1922
Location: Riley TWP Michigan

Posted: Sat Feb 04, 2023 7:03 pm Post subject: Re: Replacing copper bar with tefzel wire

Use the same size wire that connects the starter contactor to the starter motor.  

4AWG is used on some of Bob's diagrams.

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Joe Gores

nuckolls.bob(at)aeroelect
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Posted: Sun Feb 05, 2023 12:55 pm Post subject: Replacing copper bar with tefzel wire

At 09:47 PM 2/3/2023, you wrote:

  	  Quote: 	
		  --> AeroElectric-List message posted by: "jcohen(at)post.com" <jcohen(at)post.com>



 I am building a Vans RV7 , IO360, Z101, using B&C master and starter contactors, and an EarthX ETX 900 battery. I can’t easily use the Vans design solution of 0.125” thick copper bar, about 3” long x 0.5” wide, to connect the master solenoid to the starter solenoid, due to physical placement on my firewall and the stud orientation on the B&C starter contactor. So I want to use an insulated wire instead of the bar, maybe only 4” or so. 



 >From old posts on vansAirforce.net forum, the current here is estimated to be up to 320 amps for short periods while cranking the starter. Is that correct? What gauge tefzel wire should I use to maintain the functionality and safety of the copper bar? 	


   I'm skeptical of that current number . . . nonetheless,

   a 4AWG piece of wire would be just fine. If you don't yet

   have the wire, get a chunk of welding cable from a local

   welding supplies shop. MUCH more flexible and installer

   friendly. Be gentle on yourself too . . . don't make the

   jumper run a tight, straight line between studs. Make

   it a leisurely hop between mounting locations so that

   you can exploit that flexibility; i.e. a 6" piece

   of wire is about right for connecting studs 4" apart.



 

 

   Bob . . .



   Un impeachable logic: George Carlin asked, "If black boxes

   survive crashes, why don't they make the whole airplane

   out of that stuff?"

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jcohen@post.com

Joined: 10 Mar 2022
Posts: 17

Posted: Thu Feb 09, 2023 3:35 pm Post subject: Re: Replacing copper bar with tefzel wire

Thank you for your comments. Welding cable it is!

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