Mastering EV Cables Work for Connections That Spark!

COMPILED BY EVBG STAFF AND LEGACY EV

I F you want plentiful power out of your electric vehicle, you need the ability to move a lot of current from the battery pack to the motor at high voltages. Doing so requires working with large cable that’s capable of high continuous and peak current ratings. These cables need to be securely terminated at both ends, which can require tools and skills found outside of traditional hot rodding. This guide will serve as a starting point so that you can get watts where they are needed in your EV build.

MEASURE AND CUT IT

The first step in running your HV lines is to cut your cable to the proper length. In most cases, we will terminate the cable on one end, leaving the other end longer than necessary. Run the cable along the exact path where it will be installed once the build is complete, securing it to the vehicle if necessary. Make sure the cable has no excess slack but is not tight. Once you’ve arrived at the location where the other end of the cable will terminate, mark and cut the cable to length, making sure you are taking into account the space the lug or connector will occupy. A pair of highleverage cable cutters is the best tool for this job.