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DIY Super Winch 12 volt extension-jumper cable

Super Winch extention cable


The plan is to modify one end of a good pair of jumper cables with the above quick connector, and hook the other quick connector to the Super Winch.

A 20 foot set of jumper cables is about 4 feet shy of making it to the battery. What I need to research is the possibility of only having one strand reach all the way to the positive portion of the battery and have a frame contact near the bumper to connect a shorter negative strand clip to. This would allow me to splice enough onto the positive side to reach the battery and have plenty left over to make a short strand for the negative frame connection.

I know a splice looks a little sloppy, but is it still just as functional as a continuous strand?



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This winch can pull 320 ampere when running slowly at full load. The startup current can be even higher. This is significantly more than e.g. the starter motor.

For normal electrics, I'd say a soldered splice should be as good as the original wire. If you don't solder the splice, I think the resistance will be too high, heating up the cable.

But for a high-current application like this I'd prefer as few connections as possible. Better to go to a hardware store and have cables of the right rating cut to size and connectors crimped on.

To get a high startup torque, the coils of the stator and rotor of motors like starter motors and winch motors are generally wired in series. If the motor is standing still, there is no changing magnetic field to induce back-emf (practically raising the resistance) in the coils, so it draws a lot of current. If such a motor is prevented from rotating with the power on, it will eventually overheat and break (short out). That is why the winch whould have a built-in circuit breaker. If it is a fuse; get some spares. :-)

Comment by Roland_Smith Wed Sep 28 17:31:31 2011
In a pinch, I have used copper tubing crimped over the wire, soldered and taped or shrink tubing over the connection. Also copper tubing can be smashed over both ends of the wire with a hole drilled in and bolted together. Just make sure the copper tubing is cleaned and polished inside to accept the solder.
Comment by zimmy Wed Sep 28 21:07:10 2011

Roland-I wasn't aware of back-EMF. That piece of information has pushed me over the edge into not having a splice.

Zimmy-If I had to make a splice without a trip to the store I would try that copper pipe trick. Sounds like it could be a solid connection if it was done right and soldered completely.

Comment by mark Thu Sep 29 08:51:41 2011

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