Connecting battery to controller - wire too short

Nosweat

Pedelecer
Sep 2, 2019
95
29
Following a recent problem with my torque sensor (Woosh crank kit) I'm moving over to the bottom bracket torque sensor. The controller in the Woosh kit is intended to go in a seat pack behind the saddle but the cable to the battery is only about three inches long. All other cables reach to their intended locations.

The only way I can see this working with the supplied kit is if I attach the controller at the bottom of the downtube immediately next to the battery (see photo - my fingers are on the bottom of the downtube battery cradle having removed the battery). But is that a sensible position to mount the controller given the connector type and the relatively open position close to the ground? If not, what kind of cable should I use inbetween battery and controller?
Wiring.JPG
 

thelarkbox

Esteemed Pedelecer
Aug 23, 2023
1,681
525
oxon
How much new wire do you require? you can get xt90 connectors as used for heavy duty RC batteries with circa 15cm pre wired 10 awg silicone sleeved wires so upto 30cm with a male and female pair?

google suggests 10 awg wire is ok for a 30amp draw or less..
 

saneagle

Esteemed Pedelecer
Oct 10, 2010
9,514
4,243
Telford
The controller should be in a box, like this, which you can get from Aliexpress or Ebay. If your controller is 17A or more, you probably need the next size up:
64392

While you're waiting for it, you need to open up the battery box and remove that aluminium piece that has the connector on it. Unsolder the two wires from the connector and solder on two more 14g wires the right length to reach the controller. Make sure that you get them the right way round. Cut the red wire inside the aluminium box and solder in a 25A fuse. Don't forget to insulate the joints with heatshrink otherwise it might short on the aluminium. Cut the two connectors off the controller's battery wires and solder the two 14g ones to them directly. You don't need any connectors because the battery is removeable.
 

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