Battery Cable Length

I suspect they just buy bulk cable and add the ends.  Look at ends and if they are moulded on then stock cable length - if bolted then made up cables.  Long runs should use heavy cable - some say welding cables (are the 0 or 00 gauge?  Running bulk cable without ends should be easy - Maybe could even cut ends off old and solder or clamp new cable on and pull through from other end.

This is probably what they use - or the cheaper lead colored ones.

What do you mean by "Standard" length?  VS battery cables are probably the same as CMC or JPS, but only "Standard" for those Speedster cars - They are not "Standard" VW sedan length, which is about a foot longer.  

Disconnect the cable at both ends and pull it in stages to the front.  At the front of the footwell there is another rubber grommet to go through and then just follow it to the battery area.  I guess the entire process would be to pull up the carpet a bit right along the side of the tunnel, pull the old cable in stages and lay the new one right where the old one went.

It might be easier to clip off the terminator on the starter end to let it pull through easier, but that's up to you....It should pull right through regardless.  It runs along the passenger side right next to the central tunnel, under the carpet, and should have a rubber grommet going through the chassis just behind the seat.  It is an easier process if you remove the seat first.  

I had to run a new Positive battery cable after I installed my heater, when I moved the battery and needed a longer cable.  Any decent commercial truck supply place has HD battery cable in bulk length - you just tell them size, how long you want it and they cut it.  They'll probably also have the same crimp-on ends so bring along your existing cable and they can match the length and crimp on new ends the same as what you have - that's a nice luxury.

As for size, I went with 1/0 gauge for my car.  Remember, you're asking for 100 amps at about a ten foot length when the starter is turning so don't cheap out on it.  Welding cable is really nice and very flexible because it's made of lots of fine wires.  It's also quite a bit more expensive than Auto/Truck cable because of the flexibility so I wouldn't recommend it unless you really think you need it to make some tight turns.

And why are you replacing your battery cable after 14 years?

12ft. and but the time you rout it from the battery to the starter you will have little if any left over.

Alan probably means 12 foot long.  Usually, just the ends get corroded so if there is a little extra length then cut off ends, clean and reapply new ends.  I like to solder ends but others think that makes the ends inflexible.  It under gauge wire is used - I'd upgrade to thicker wire.

12' sounds right.  I bought 15' and had them crimp only the starter end on.  The battery end was a little non-stock because of the fused, heater 12V wire, so I went with a bolt-together as Wolfie showed but had to cut off about 3 feet, so there you go.

Wolfie must have one helluva soldering gun - or he uses a torch.

If you don't have the right tool to crimp an end on a cable you can place a machine screw parallel to the terminal and crimp it in a vise or a vise grip. 

Alan Merklin posted:

If you don't have the right tool to crimp an end on a cable you can place a machine screw parallel to the terminal and crimp it in a vise or a vise grip. 

I've been know to solder, then crimp in a vice ( or hammer and chisel ) making things a bit flat, then drill a hole and put a small bolt through with a nylock nut on the other side.

An odd thing happened on the way to Carlisle one time. Had a new battery installed at home and when within 100 miles of Carlisle we stopped for lunch. Went to start the car and zero happened. A quick look under the hood revealed that the spare tire had moved a bit forward in the frunk and nudged the positive cable right off it's post. Easy fix but it's one more thing to look out for.  

You can use #4 welding cable......available at welding supply outlets at normaly lower prices than at your auto parts shop.....

00 cable. Marine bolt-through ends. 12 feet is just enough.