Common high current connectors - and my opinion on them

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Matt Gruber
100 kW
100 kW
Posts: 1352
Joined: Feb 08, 2007 11:02 am
Location: New Smyrna Beach FL

Re: Common high current connectors - and my opinion on them

Post by Matt Gruber » May 01, 2014 7:57 am

is anyone else making their own? instead of that bulky and expensive plastic housing, i'm trying double heat shrink over male/female generic connectors. i have substituted a fuse for one connector in each string. this way the string comes apart easy and is fused. For charging i use one male spade, and one female on opposite sides of the bike so they can't ever touch, even in a crash. can't hook it backwards and it is double heat shrinked. costs close to nothing to make.

has anyone checked the voltage drop at rated amps? i'd expect old fashioned twisted copper with a wire nut to be superior. i'm using this old school method where ever i don't need a fast disconnect, but don't want to solder. There should not be ANY voltage drop because the twisted wire doubles the copper at the twist.
2006- added fail-safe controller bypass circuit with power boost to Razor MX500 using 2 80amp relays.
Now testing JB Weld cell fuses. No more soldering to a bare cell for a repair. Connect it safely with JB Weld cured with slight clamping pressure for both a good connection and thermal fuse protection.
Why build a pack from scratch? I buy tool packs instead.

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100 µW
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Joined: Apr 24, 2012 9:04 am

Re: Common high current connectors - and my opinion on them

Post by simpes » May 23, 2015 10:00 am

There are hobbyking XT90 anti-spark connectors. They use a 5.6 ohm pre-charge resistor. There is another thread discussing about it here: ... 35&t=63210

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