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Old 07-25-2014, 06:16 PM   #7
hatzie
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Join Date: Oct 2008
Location: Wentworth, NH
Posts: 5,022
Re: Battery cable routing

You could take it as an opportunity to reroute the starter wires in a safer location.
I was installing a 6.5L diesel engine so I got rid of the wires running down the bellhousing in that steel tube next to the exhaust. I routed longer replacements for those three wires to a universal starter solenoid next to the battery tray.
The starter now has a single 4ga SGX wire along the oil pan just like the original did in vinyl covered P-clamps. It runs from the universal starter solenoid to the starter batt terminal. It only has juice when the universal solenoid is tripped so I added a 14ga loop from the batt terminal on the starter solenoid to the S terminal so it engages as soon as there's juice from the universal solenoid.
The new wires run neatly along the firewall and inner fender in split poly loom up away from the exhaust manifold instead of right behind the headpipe.

The Universal solenoid has four wires on three studs.
  1. Main battery power stud.
    a. 4ga RED SGX battery power from the RH battery + side post.
    b. Main power feed for the cab that usually runs from the starter to the firewall junction block. (14ga fusible link wire that's pulse welded to 10ga Red SXL wire with adhesive heat shrink cover for the welded splice and both ring terminals)
  2. 4ga SGX High amp feed to the starter only energized when ignition switch is in START.
  3. 12ga longer replacement SXL Purple "Start" wire from firewall bulkhead plug.
The RH to LH battery cable runs neatly along the radiator mount in split poly.
The RH & LH SGX black ground cables run to a stud welded on the frame and a heavy copper braided ground strap runs from those frame studs to the block and a 12ga black SXL wire runs from that stud to the radiator support ground stacks on both sides. There's another ground strap from the bottom of the cab to the frame.
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1976 Chevy K20, 6.5L, NV4500/NP208 SOLD
1986 M1008 CUCV SOLD
2000 GMC C2500, TD6.5L, NV4500
2005 Chevy Silverado LS 2500HD 6.0L 4L80E/NP263
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