Building Battery Cables - LSxHumvee

Time to build some new battery cables for the Humvee. Relocating the 12v battery to the front of the truck required new battery cables to the starter and I needed to add some heat protection as they run beside the exhaust manifold. I also take some time to put an inline fuse on the starter relay wire for security.

[@chrisnikkimcdonald8867]

You are making great progress. One important note. The fuse holder terminals should be crimped and pushed in from the back of the plastic shell housing. There is a tab on the metal connector that locks in and lets it be serviced separately from the plastic shell. It looks like it clicked in for you so I may be wrong. Generally they all go in from the rest.

[@doughboy1966]

Great update video. There is not much room around the starter for wiring due to the exhaust.

[@RakTheGoose]

awesome video, one note is to replace the plastic ziptie on your battery cable heat sheath with a steel ziptie.

[@LSXHumvee]

Good call, I didn't even think about that

[@BMD11000]

That looks like CCA or something. If you get copper wire, it will actually be a little smaller in the same gauge. Plus, you can use a crimping tool about half that size (and about $40) for cable up to around 1/0 or so. Love the vids and I'm not criticizing, just trying to be helpful for whatever is next.

[@tuttdog1234]

That starter looks so tiny compared to stock 6.5 one

[@LSXHumvee]

Yeah it's crazy how big the alternator and starter are on the stock Humvee

[@rjfowler189]

Awesome build! Out of curiosity, what kind of gas mileage did you get when this was running?

[@LSXHumvee]

With the diesel I'm not sure, probably 10. With the LS and sniper efi, around 12 realistically.

[@delpierro6222]

hhhhhhhh