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Here is what I've done on 3 of my trucks. Currently running this setup on all three with NO issues. In each case I used the existing cables, just hacksawed the lead lugs off and swagged on solid copper welding cable lugs with 3/8 diameter hole and used the Marine style battery lugs with wing nuts.
I bought a cable swage tool from NAPA for about $40 so I can do my own cables.. it's proven to be a good investment.
I do not solder the lugs. I use DC4 to coat the end of the cable and inside of the lug before I swage it, then slip on a double layer of heavy gage shrink tubing [shrink on one layer, then shrink another over that with over lap on the outside layer].
One thing I DO use is a metric wave washer under the wing nuts to hold good contact.
Working on the truck, it's now a piece of cake to disconnect the batteries, before I do anything electrical.. I coat the connections with DC4 and the battery lugs, also use the red and green anti corrosion biscuits under the lugs.
The Marine lugs stand a little taller than you will like on the driver side ground lug.. clock it to clear the hood. You will be good to go for way less than stock battery cables with the terrible, impossible to find, impossible to get tight positive lug.
Good luck
ilburners.net
.....yah I don't get on much anymore....lol.....I feel like the old gang I knew has moved on! Lol! The wealth of knowledge here from young and old is excellent and you can't stay away for too long especially when trying to keep these old gals on the road!
