Winch Wiring Advice Needed

Thanks for the input. Didn't realize not taking the negative back to the battery would be a big issue as it just grounds to the frame there anyway. It was initially to save having to buy an additional 15-20 feet of 4/0 cable but I can definitely change my diagram to take it back to the battery terminal.

I do like your approach as it's very KISS. Keep it simple, stupid. I'm going to think about this approach more.

 

I used 1/0 wire... yeah I know it isnt large enough enough for the winch at maximum current. (but i intend that the fuse will blow at 300 amp anyway)

https://skycraftsurplus.com/10awg-nickel-plated-aircaft-wire-white-m227593-01-9-rp8049.html
But note, this is nickle plated wire so it is not good for soldering, best for crimp connections

 

Actually, rating for the 1/0 wire I am using is much higher than 170A. That is a 260C wire.
(that said, my installation does not use 260C connectors, and it will definitely exceed allowable voltage drop... so you are definitely correct that larger wire is recommended)...

 

Hey all, thanks for all the critiques and suggestion. This was exactly what I needed to help me get this project going.

I thought I'd post an update to show what I've decided and am moving forward with. I've only just ordered everything and have not started the installation.

Overall Deciding Factors:
1) do it once, do it right
2) maximum ease of use
3) no regrets

The wiring:


From the battery to the front hitch I'll need about 5' of wire and to the rear hitch I'll need a 20' of wire.

The winch: I'm giving it a chance. Got it for only $450 using a 25% off coupon. Got the 2 year extended warranty. At a 12k pull, it draws 485 amps.

I'll be using all 4/0 welding wire throughout.

Kit of parts:
Anderson Connectors (3):
https://powerwerx.com/anderson-sb-connectors-sb350-350amp

4/0 Wire Lugs (10 pk):

$20 SELTERM 10pcs 4/0 AWG - 5/16" Stud - Battery Lugs, Heavy Duty Wire Lugs, Ring Terminals, Battery Cable Ends,0000 Gauge Terminals, UL Bare Copper Eyelets Electrical Battery Terminal Connectors

https://smile.amazon.com/gp/product/B073CMF6ZV/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1

500 Amp ANL Fuse:

THOR Manufacturing THANLFB-500 500 Amp ANL Fuse with Block

https://smile.amazon.com/gp/product/B01M2DF03H/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1

4/0 Welding Wire (50' total):
https://www.ebay.com/itm/50-4-0-EXC...COPPER/291883364098?ssPageName=STRK:MEBIDX:IT

Switch (didn't end up ordering because winch came with one):

$40 Ampper High Current Battery Switch, 12-48 V Battery Master Cut Disconnect Switch Isolator for Marine Boat, Ship, Yacht, RV, Truck (On/Off, High Current)

https://smile.amazon.com/gp/product/B07PN9DR6C/ref=ox_sc_act_title_1?smid=A2ZNPLJCY5BQIU&psc=1

Let me know if you see anything that can be improved upon. I'll post an update once I get it installed. Or sooner if I run into any issues!

 

A few additional items you will need/want
Big wire crimper
Heat shrink to put at terminals
Additional wire protection to add at locations of additional risk (like some corrugated tubing, etc)

 

Yep, I have all those from previous projects. Didn't list them because those are just basics for electrical work to me. I forgot to mention I did get a PET abrasion sleeve for the welding wires.

Abrasion sleeve:

$12 25ft - 1" PET Expandable Braided Sleeving – Black – Alex Tech Braided Cable Sleeve

https://smile.amazon.com/gp/product/B073YLYBJF/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1

 

Your design looks good. Two websites that I like to use for getting quality electrical components are:

https://gregsmarinewiresupply.com/

https://m.delcity.net/

 

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