winch wire size

[keel5]

I got myself a new Warn XP9.5 winch to replace the old Harbor Fright job. Now I have some questions about wire size. I looked through the search results but didn't find anything.



I want to mount the solenoid pack under the dash above the driver’s feet. I have some #2 welding wire and I was wondering if that was going to be good. Bought the wire thinking I was going to mount the pack under the second battery until someone pointed out that the engine compartment probably wasn't a good idea because of the heat. Now with the 8 to 10 foot run I'm not sure the wire is going to be sufficient enough for the 480 amps Warn says the winch draws at full load. The wires that come on the winch are #2. The + & - are about 6 ft long and the wires from the solenoids to the motor are about 2 ft long.

So, should I use the #2 wire that I already have or should I get something different?

[Kejtar]

I got myself a new Warn XP9.5 winch to replace the old Harbor Fright job. Now I have some questions about wire size. I looked through the search results but didn't find anything.



I want to mount the solenoid pack under the dash above the driver’s feet. I have some #2 welding wire and I was wondering if that was going to be good. Bought the wire thinking I was going to mount the pack under the second battery until someone pointed out that the engine compartment probably wasn't a good idea because of the heat. Now with the 8 to 10 foot run I'm not sure the wire is going to be sufficient enough for the 480 amps Warn says the winch draws at full load. The wires that come on the winch are #2. The + & - are about 6 ft long and the wires from the solenoids to the motor are about 2 ft long.

So, should I use the #2 wire that I already have or should I get something different?




I believe that I used #2 with the warn 8K and the wires are about 6' each (I've mounted it inside the engine bay on the drivers side kind of in the area where the airbox used to be). I haven't had any issues with heat during HOT summer days in the SoCal desert during long pulls.

[dan89XJ]

I got myself a new Warn XP9.5 winch

Nice ! I was looking at those the other day.. did you get a good deal on it ?

[Harvo]

Those are awfully big wires to try and run into the cab. Then you still have to use your remote. Something just as easy would be to mount the noids under the hood or on the winch, then run regular sized wires from it to a switch in the cab on your dash. Then you have control in the cab without needing to use the remote, and no hassle of stuffing those fat wires under the dash and through the firewall.

[Kejtar]

Those are awfully big wires to try and run into the cab. Then you still have to use your remote. Something just as easy would be to mount the noids under the hood or on the winch, then run regular sized wires from it to a switch in the cab on your dash. Then you have control in the cab without needing to use the remote, and no hassle of stuffing those fat wires under the dash and through the firewall.
Yikes, I didn't catch that. Yeah, running them inside would be a PITA. Anyways in your sig it shows that you have a 99. If you have cruise control, get yourself one of these (http://www.kwanms.com/products/twc+/twc+.htm). I got it and I love it. I believe I have the first one that was put in an XJ :D

[keel5]

Nice ! I was looking at those the other day.. did you get a good deal on it ?



Yeah I got a damn good deal on it. I got it from this guy Sportztrailers (http://www.andale.com/stores/sf_itemHome.jsp?lid=282101932&cid=11582461&mode=1). He also sells on eBay. $850 with free shipping (it was here in two business days) is the best price anywhere.





Those are awfully big wires to try and run into the cab. Then you still have to use your remote. Something just as easy would be to mount the noids under the hood or on the winch, then run regular sized wires from it to a switch in the cab on your dash. Then you have control in the cab without needing to use the remote, and no hassle of stuffing those fat wires under the dash and through the firewall.





As for running the wires inside. I know it will be a pain in the a**, but I don't mind. I just want to get the box off the front bumper. The new box is fairly large with the cover on it and if I mount it inside I can do away with the cover. I would remote the remote plug back to the front of the truck and already plan on a home brewed in-board switch. I am going to look at mounting it under the driver side battery again since Kejter says he has no problems with heat. It’s just the longer runs of #2 wire that have me concerned.

[Kejtar]

As for running the wires inside. I know it will be a pain in the a**, but I don't mind. I just want to get the box off the front bumper. The new box is fairly large with the cover on it and if I mount it inside I can do away with the cover. I would remote the remote plug back to the front of the truck and already plan on a home brewed in-board switch. I am going to look at mounting it under the driver side battery again since Kejter says he has no problems with heat. It’s just the longer runs of #2 wire that have me concerned.
Is your battery sealed? If not then I would not mount it under the battery. Also if you place it under the batter it does end up being somewhat low and inacessible. That can cause two problems:
1. If you end up going through a stream or a creek it might get submerged
2. If something works loose or you need to check wire connections, it's going to be PITA to get to it.

I placed mine next to the auxilaury fan:
http://kejtar.com/XJ/tech/WinchWiring/

[keel5]

Is your battery sealed? If not then I would not mount it under the battery. Also if you place it under the batter it does end up being somewhat low and inacessible. That can cause two problems:
1. If you end up going through a stream or a creek it might get submerged
2. If something works loose or you need to check wire connections, it's going to be PITA to get to it.

I placed mine next to the auxilaury fan:
http://kejtar.com/XJ/tech/WinchWiring/

I don't have much of an option. Its either under the battery or in side. I just need to know if #2 wire is going to be enough.

http://www.the-jersey-devil.com/photopost/data/500/488The_Excuse_2-med.jpg

http://www.the-jersey-devil.com/photopost/data/500/488Full_shot-med.jpg

[Harvo]

Looks like you have a sealed battery. Leakage shouldn't be an issue.

[Kejtar]

http://www.the-jersey-devil.com/photopost/data/500/488The_Excuse_2-med.jpg

Can you put it under the cone filter? towards the cab from the battery?

[Wiley Coyote]

Kejtar, Do you have an in cab controller or a wireless remote for your winch? It seems to me you would have to open the hood to be able to use your winch. That’s fine if you are sitting there pulling some one else out, but kind of a pain if you have to drive and pull yourself out. I guess just close the hood gently on the remote cable? :eek:

Disreguard, seen where you have the cruze control mod. :laugh3:

[Roxtar]

Those are awfully big wires to try and run into the cab. Then you still have to use your remote. Something just as easy would be to mount the noids under the hood or on the winch, then run regular sized wires from it to a switch in the cab on your dash. Then you have control in the cab without needing to use the remote, and no hassle of stuffing those fat wires under the dash and through the firewall.2X

[Roxtar]

since Kejter says he has no problems with heat. Now I see why you're making this mistake.
You've been listening to Ketchup. :D

You must be new.

[CartsXJ]

I don't have much of an option. Its either under the battery or in side. I just need to know if #2 wire is going to be enough.

http://www.the-jersey-devil.com/photopost/data/500/488The_Excuse_2-med.jpg

http://www.the-jersey-devil.com/photopost/data/500/488Full_shot-med.jpg


How do you like that Mean Green dual battery set-up? I've had my eye on it since I first saw it in Quadratec. Look pretty sweet. Is there only a certain series of battery you can use it with? I would like to put in a Blue Top for winchin' and light duty and just use my Red Top for startin'.

[Roxtar]

How do you like that Mean Green dual battery set-up? I've had my eye on it since I first saw it in Quadratec. Look pretty sweet. Is there only a certain series of battery you can use it with? I would like to put in a Blue Top for winchin' and light duty and just use my Red Top for startin'.$165 for a battery tray, two steel battery clamps, and a cone filter seems kinda pricy.

[CartsXJ]

$165 for a battery tray, two steel battery clamps, and a cone filter seems kinda pricy.


True, I'll give you that one. except for the fact the cheapest I've seen a cone filter system would be rusty's at ~$50 plus shipping and then to spend the time fab'ing the tray, really depends on how much your time is of value to you. But for me, unless I absolutely need it done or have the tools and materials around to do the mod, I'll spned the money on it. Granted I just got a new welder for X-mas and I have a feeling that there will be more "materials" lieing around to do my own mods from now on, but look at some of the other "open air" filter systems out there, ~$175 and up. At least this way you get a dual battery mount included.

[keel5]

The Mean Green dual battery set up leaves a lot to be desired. I don't have a welder and a lot of experience fabing, so it worked out for me. The filter is trash; I used it until it was dirty and ordered a K&N. The filter tube is just like Rusty's. It’s just a tube with a piece of strap welded to it to mount to the fender well. The battery tray is nice and stout but since it mounts to the sheet metal of the fender well it still has a little vibe. I had to do a LITTLE grinding on it where it hit because of the vibe. I bought a new yellow top to go in the tray but it hit the radiator fill neck. I had an old style red top and it fits perfect. I used the Painless dual battery control system witch I like a lot.







As for the Mean Green set up. Do I like it? Yes now that I helped it a little. Is $165 a lot for it? Yes.