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Thread: 4 AWG with 3/16th lugs

  1. #1
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    Default 4 AWG with 3/16th lugs

    I'm trying to use one of these marine fuse blocks to distribute 24v at 100amps to 8 controllers.
    DC Subpanel_.jpg

    https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

    The fuse block is rated to take either 4AWG or 6AWG wire. However, the screw terminal for the positive and negative on it is a #10-32 which ideally takes a 3/16" lug.

    However, I can't find a 3/16" lug for 4 AWG wire anywhere. Anybody has any ideas for a supplier that has these or alternatively can make custom lugs?


    I can find 1/4" but they're too big to make good all around contact on the pad. I can also find 3/16" for 6 AWG, but the voltage drop on 6 AWG is too high.
    2019: ??? pixels, 24 E682's. Centralized 24v power distribution.
    2018: 2000 pixels, 2 E682's. 4 LOR
    2017: 33069 pixels, 20 E682's. 50 A/C with 2 LOR
    ...
    2011: 64 A/C channels with 5 LOR

  2. #2
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    Default Re: 4 AWG with 3/16th lugs

    I have had the same issue with some of my fuse blocks. I just used a smaller connector and stripped back a few strands of wire to get it to fit in the smaller connector. The voltage drop over such a short distance is minimal

  3. #3
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    Default Re: 4 AWG with 3/16th lugs

    Hi, I’ve had to make adapters for this sort of thing before. I used some copper strip, shaped and drilled one end to fit the terminal of the fuse board and then drilled the other end to suit the lug on the cable, a sort of figure of eight adapter. Worth considering if you can’t find the correct lugs.

  4. #4
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    Default Re: 4 AWG with 3/16th lugs

    Use 3/16" ID (or #10) washers on the larger (#4 AWG x 1/4" ring) connector. You may need to file the sides of the lower washer(s) to fit between the barriers around the screw terminal (or file down the barriers). You can build up from the smaller base to a larger contact area for the ring connector.

  5. #5
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    Default Re: 4 AWG with 3/16th lugs

    Quote Originally Posted by ags0000 View Post
    Use 3/16" ID (or #10) washers on the larger (#4 AWG x 1/4" ring) connector. You may need to file the sides of the lower washer(s) to fit between the barriers around the screw terminal (or file down the barriers). You can build up from the smaller base to a larger contact area for the ring connector.
    I'm not a fan of running 100 amps through a washer that wasn't specifically designed for it. You can easily weld two washers together with that amount of current.

    Any impurities or holes in it and it will explode at high load.

    A washer that is just providing clamp force on the other side is fine, but on the pad side it would be actually conducting.
    Last edited by deonb; 11-15-2019 at 05:49 PM.
    2019: ??? pixels, 24 E682's. Centralized 24v power distribution.
    2018: 2000 pixels, 2 E682's. 4 LOR
    2017: 33069 pixels, 20 E682's. 50 A/C with 2 LOR
    ...
    2011: 64 A/C channels with 5 LOR

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