[pjtezza]

Like @sschefer, I also prefer the tin coated marine style wire. It is also nice that they have duplex and triplex options for 12V and 120V in the gauges you need in an RV. Marine style adhesive lined butt connectors are very reliable. I'd say that Ancor is the name brand for marine wire and butt connectors. It is what they sell at West Marine. But yes, this brand is expensive, even on Amazon. Digging around on Amazon, I've found other brands of this style of wire for less: https://www.amazon.com/gp/product/B00EADW6SW/ and https://www.amazon.com/gp/product/B00MI52TA4/ for example. This is mostly what I used in my van. I can't say about long term, but it looks good and has worked well so far.

For my 1/0 main cables, I used all copper welding cable. I bought it off Amazon, but I'd check electrical supply houses if you have the time.

I would not recommend THHN. It is just too hard to work with.

For connectors, I recommend a high quality ratcheting style crimper for normal stuff and hydraulic crimpers for 1/0 plus heat shrink. There is a guy on YouTube that compares pull out strength for various connectors. I'm pretty sure Ancor was the best, but all the ratcheting crimpers worked well. The basic type of crimper doesn't really work at all.

I am still working on finding a good solution for 12V plugs for things like the water pump, that I'd like to be easy to install and remove. I tried some inexpensive waterproof connectors from Amazon, but they suck. I recently ordered some connectors I saw electrical bike builders using. They look great, but I haven't had a chance to try them yet.

 

[pjtezza]

Have you looked at Anderson Powerpoles or SB connectors?

https://powerwerx.com/anderson-power-powerpole-sb-connectors

They come in different amperage ratings (15A to 350A) are polarity keyed. They have a very reliable self-wiping contact design. Also, lots of accessories available.

I had not seen the Powerwerx and they look nice - thanks! Here is what I'm about to try: https://www.amazon.com/gp/product/B00XBLLG5S/. If the soldering is too much of a PITA, I'll give Powerwerx a try.

 

[pjtezza]

They also have Weather pack connectors which is the standard for sealed 12V connections in the automotive world. You will need special crimp tool and a little bit of patience to use Weather pack connectors but the effort is well worth it. They are very easy to disconnect even with on hand. Weather pack terminals are good up to 25A iirc. Anderson power pole connectors can carry more current (they have more than one size) but aren't sealed. They are designed more for non permanent connections like winches, trolling motors and the like. The is also Metri-pack which is similar to weather pack but has some sizes that can carry more current.

The connecters I tried and didn't like look like the Weatherpack connectors. My issue wasn't with the crimp. IMO, the pin and hole used to complete the circuit are too difficult to get aligned. If they aren't aligned when you push the connectors together, the pin can get pushed out of the back of the connector just enough to break the circuit but not enough to be easily visible. In my case, I've been taking my refrigerator in and out a fair amount and this connector let me down one too many times. The ones I installed on the water pump and furnace are working fine, but I only connected them once. Maybe I'm just having a quality issue. They might be rated for 25A, but they don't look like they can handle much current - more like electronic than electrical.

 

[pjtezza]

I got a chance to give the XT-60 connectors a try yesterday. Some photos are attached. They are inexpensive and seem nice. If you prefer to crimp rather than solder, it is possible to buy them with soldered leads. There is available a larger XT-90 connector with an anti-spark feature. You have to be a bit careful when buying these connectors: According to the reviews I read, there are some inferior clones on the market that have substantially less metal and inferior plastic that melts when the connector is soldered.

 

[pjtezza]

I like the marine wire because it comes in a selection of sizes and configurations that are handy for building RVs. The tin coating maybe overkill inside an RV, but it doesn't have any negatives that I know of. However, just because it is "marine," I don't buy my wire from Ancor or West Marine because is would be very expensive. I've had good luck buying bulk spools from suppliers on Amazon. Sometimes, you have to get creative to find the size and configuration you want.

 

[pjtezza]

From what I have seen, Ancor and West Marine wiring products are top quality, so if you can get those cheaper and/or more conveniently, go for it. I looked at my order history and I bought most of my marine wire from Lawrence Marine Products. They have a pretty good selection of tin coated wire and lugs, but their quantities may not match your application.

• I end up using a good deal more wire than what I measure for, even in the large gauges.
• I use a hydraulic crimper for the big gauges - one with dies for AWG is ideal - check Amazon for bargains
• Pure copper or tin coated copper lugs with adhesive lined heat shrink for the big gauges
• High quality ratchet crimper with AWG dies for the smaller gauges
• Non-insulated connectors with heat shrink for the small gauges

 

[pjtezza]

Why non-insulated? due to cost?

The insulation makes the crimping more difficult and the results are bulky. I always heat shrink, so the insulation isn't necessary.