[daloudin]

Measure the OD of the welding cable insulation and get the proper size strain relief for the cable and then enlarge the hole to mount the strain relief.
strain relief

 

[daloudin]

Oh man never seen those before, I want to redo my wiring now 😂

The only issue with them is that once that collar squeezes down on the insulation there's not much leeway to bend the wire very close to whatever bulkhead you are going through, but as long as you've got some space on each side they great. We use them on off road vehicles and have confirmed they are watertight with no leakage when installed properly.

 

[daloudin]

Yeah, I just read that they are only good for 100A which is not enough since I have a 320A HO alternator. However, I found one on Amazon rated at 440A continuous with peaks at 550A, so I'll probably go with that since my alternator is High Output. I can also go from 2/0 welding wire to 4/0 welding wire. I could even do the big 4 and drill two holes...one from alternator to battery positive and one from the alternator frame to the battery negative. This is a game changer for me.

High current through panel battery connectors

I ****ing love this place...thank God for DIYMA!!!

As @Slave2myXJ pointed out above; you will be much better off with the only connections in the wire at either end. The 2/0 wire is plenty for any reasonable distance and you still need proper tools to make those connections on each end. The tools for 4/0 are starting to get into the size where you have to purchase separate dies for each wire size and use hydraulic crimpers (unless you intend to solder the ends on and that's a whole 'other' ball of wax)... additionally, that through post uses stainless nuts on an unknown metal plated copper post so if your wire end is brass then you've got copper to brass to stainless to mystery metal to copper and back again in dissimilar metals to cause dielectric changes, corrosion, resistance and noise.

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[daloudin]

Luckily I have a 16 ton hydraulic crimper so that won't be a problem. Well, back to the grommet...I can forget about the big 4. Running one run of 2/0 or 4/0 wire will be difficult but two runs is going to be a pain in the ass. Thanks for the advice.

The rule of thumb (unless your cable mfr says otherwise) is 2/0 is good for 400 Amps up to 50 feet.

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