Suppliers for wire harness upgrade?

[E=IR]

I want to build a new wire harness for my WE BD36. I am moving to 48V and want to switch from trailer connectors to powerpoles, since I just vaporized another connector all over my hand by mistakenly connecting two power sources together (argh).

Anyone have a good source for parts? I am looking for the following and would prefer to buy from one supplier if possible.

24 pack, Anderson Powerpoles, 45A, for 10 gauge wire
2 30A fuse boxes and fuses, double boxes would be OK
2 DPDT Switch, 30A
24 F2 female disconnect (1/4") shielded, for 10 gauge wire
heat shrink

Also, what is the best way to split a connection off of a battery pack? I want two pigtails, one for permanent connection to the controller, one for the charger. In the past I have used butt connectors and jammed two wires into one end. Is there a better way?

Thanks

 

[Johnbear]

These guys have most of what you need and there prices are pretty good. http://www.powerwerx.com/

 

[Drunkskunk]

What he said

As for the chargering port. the best way is to open up the battery, and solder on a second set of leads for a charging connector. But they way you had it is fine. the charging connector can use thinner wire.

 

[Link]

These guys have most of what you need and there prices are pretty good. http://www.powerwerx.com/

Yeah, and they have a fast turnaround time. I got my stuff a day after I ordered it.

Granted, I commented on that at my house, got asked where they were, and found out they're in the industrial district that's like ten miles from me.

 

[E=IR]

I ended up buying the powerpoles from powerwerks and the terminals from DigiKey. And a charger from electricrider.

Ouch, but this should be everything I need to get to a 48V system.

Thanks

 

[SamSpeed]

I want two pigtails, one for permanent connection to the controller, one for the charger

What about solder? Would that work? It does not offer quick release, but it makes a stout, low resistance connection. I'm thinking along the same lines, to have multiple takeoffs.

Or how about wirenuts for those connections that you seldom want unconnected. Anyone have opinions about this?

 

[Link]

I want two pigtails, one for permanent connection to the controller, one for the charger

What about solder? Would that work? It does not offer quick release, but it makes a stout, low resistance connection. I'm thinking along the same lines, to have multiple takeoffs.

Or how about wirenuts for those connections that you seldom want unconnected. Anyone have opinions about this?

Solder would be okay, but being able to separate stuff is nice. Like if you have to leave your bike in a shady area and want to take that battery pack that makes up half the cost of the bike with you. You're going to have to disconnect stuff at some point, anyway. Powerpoles are relatively cheap, modular, and easy to work with, so I use those for pretty much everything.

Wirenuts are okay, but kinda ghetto. Taping them down is also a good idea to keep them from vibrating loose, but that makes it even more ghetto. On the other hand, the worse it looks, the less gangsters are going to want to steal it.

 

[E=IR]

I went with one of these for a splitter:

http://www.powerwerx.com/product.asp?ProdID=3821&CtgID=3823

I'm hoping it will allow better wire management.

How do the powerpoles hold up to the initial spark when connecting battery pack to controller?

 

[michaelplogue]

Do yourself a favor. They are a bit expensive, but the powerpole crimpers are well worth the money. I've tried crimping 10 guage on the 45Amp connectors by hand and it's a huge pain in the rear end.

http://www.powerwerx.com/product.asp?ProdID=3324&CtgID=3575


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