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Old 04-20-2020, 02:02 PM
martureo martureo is offline
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Join Date: May 2010
Location: DC Metro/Maryland
Posts: 13,296
Starter cable wire lug

For my 603 powered w123 project car I've decided to make new ground, battery and alternator cables as the stock ones all have issues.

One problem that I'm running into is the battery to starter cable battery lug.

This is what the one from the donor vehicle (87 300TD) looks like.





The larger of the two wires runs from the positive battery lug to the starter. Its 53.5 mm^2 (1/0 AWG).

The smaller of the two runs from the positive battery lug to the terminal block on the passenger's wheel well. Its 13.3 mm^2 (6 AWG).

The issue I'm having is trying to find a way to replicate this connection. No one seems to make a multiple wire crimp lug.

I have a few choices and I'm not sure which is the best option as space is tight (exhaust heat shield is close to the battery).

1. Use a 3/0 battery lug crimp to accommodate the 1/0 and 6 AWG wires. (.162"x1/2 +.325" = .406" and 3/0 is .410" diameter)

2. Use a battery lug with an additional connection like this.



3. Splice the wires together further down the cable.
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I recondition w123/w126/w124/w140/r107/r129/ steering boxes!


1984 300D "Elsa" odo reset 6/2011 147k
1983 300TD "Mitzi" ~268k OM603 powered
1995 E300 "Adelheid" 262k [Sold]
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