What we can build
Large-gauge power and battery cable. Assemblies and terminations from 18 AWG to 1000 MCM. The work is 1 to 3 conductor: battery, ground, starter, jumper, jump-start.
At a glance
- TerminateWe terminate up to
- 1000 MCM
- CarryLargest cable we carry
- DLO 777.7 MCM
- ManufactureLargest wire we manufacture
- 750 MCM
- AssembliesAssemblies
- 18 AWG to 1000 MCM
- StrengthStrength
- 4/0 to 1000 MCM
- WorkWork
- 1 to 3 conductor
DLO cable is the largest cable Polar Wire carries. Multi-Listed Flexible Wire is the largest wire Polar Wire manufactures.
Gauge, terminations, and tooling
Strength is 4/0 through 1000 MCM. 18 AWG is the floor by choice.
- Smallest conductor
- 18 AWG
- Compression lug range
- 8 AWG upward
- Lug and splice voltage
- Rated 35 kV, copper only
- Lug temperature rating
- 194°F (90°C)
- Stud sizes
- #10, 1/4", 5/16", 3/8", 1/2", 5/8"
- Two-hole centers
- 5/8", 3/4", 1", 1-3/4"
- Flex lug conductor classes
- G, H, I, K, M and DLO
- Workmanship
- IPC/WHMA-A-620 Class 3
Code lugs are sized for code-stranded conductor and step up one size for fine strand at 2 AWG and larger. Flex lugs match lug to wire size on Class K and on DLO. Angle lugs at 45 and 90 degrees, color coding, and sight holes are available on request. Minimums may apply.
Length and volume
Wire cut length
Length on a custom cable is the wire cut length, not eye-to-eye, unless you specify eye-to-eye. Send the cut length with the gauge and the terminations. It comes back on the quote.
Volume
Tell us the annual requirement with the drawing. Sales answers with a schedule and a price. Retail assemblies carry no minimum.
Two ways to buy
Stocked assemblies
Buy it off the shelf
Jumper, jump-start, eye-to-eye, battery, and golf cart cables on the online store.
Cable assembliesThe edge of the range
Send a drawing
Anything at 4/0 through 1000 MCM, a non-standard lug, or a program quantity.
Request a quoteFrequently asked questions
Terminations 18 AWG to 1000 MCM. Compression lugs, Class 3 workmanship. Send a drawing.
What is the largest conductor Polar Wire can terminate?
Compression lugs and splices are stocked for conductors up to 1000 MCM, rated for 35 kV applications on copper conductor, UL Listed and CSA Certified to 194°F (90°C). Stud sizes run from #10 to 5/8 inch, and two-hole lugs are specified by hole spacing on centers. Code lugs are sized for code-stranded conductor. Flex lugs are sized for fine strand and are rated for Class G, H, I, K and M conductors and for DLO.
How small a wire will you work with?
The floor is 18 AWG. Polar Wire builds heavy-gauge power and battery cable.
How long can a cable assembly be?
Length on a custom cable is the wire cut length, not eye-to-eye, unless you specify eye-to-eye. Send the cut length with the gauge and the terminations. It comes back on the quote.
Can you run a wire specification that nobody stocks?
Yes. Custom colors, striping and a print legend are private label wire, from 10,000 ft. Eight stocked wire lines are on the online store. Assemblies for retail customers carry no minimum.
Request a quote
Send the gauge, the wire cut length, and the ends. We come back with a price.