![]() Since this lower quality wire was slightly thicker, the combined strands measured 3.60mm diameter, or 7AWG equivalent.Īfter tinning this wire, its diameter was 4.48mm, or nearly 5AWG equivalent. I then cut another wire, this time a low quality, low-strand-count copper audio cable, stripped the covering off of *both* strands of wire, twisted the two 12AWG strands together, and measured the diameter. I then tinned the end of this wire, and the solder increased the thickness to 3.75mm, or ~7AWG equivalent. I measured this large single strand, made up of two 12AWG wire strands twisted together, and found that its diameter was 3.13mm, or almost as large as an 8AWG wire (see here for a table of AWG wire sizes and diameters an 8AWG wire has a diameter of 3.264mm). Next, I stripped the covering off of *both* strands of high-quality 12AWG wire, and twisted them together to make one big strand of wire. You can see the gauge printed on the wire. Since I didn't have any 10AWG wire (my largest wire I have is 12AWG), I first cut a piece of 12AWG high-strand count, very high-quality silver-coated, silicone-cased audio cable. I timed it, from the time I cut the first wire to the time I finished heat shrinking the last piece of heat shrink covering. This entire experiment, including taking the photos, took me 20 minutes, and 30 seconds. I did not try to solder wires any larger, as this was large enough for the purposes of my experiment. Results: I successfully soldered the equivalent of 7AWG wires onto an XT60 connector. ![]() Rather, cut off and solder one wire at a time to a new connector). (Note: if you ever replace battery connectors, be very careful not to short out the battery leads by cutting off both wires on the battery connector at once. My goal was to see if large gauge wire (10AWG or larger) could be soldered to the XT60 connector, in order to use this connector to replace other large, bulky, or cumbersome connectors on very large battery packs where you need less than 60A continuous current draw. My Soldering Experiment on the XT60 Connector:
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