Ordering a Custom Cable Assembly

So you know you want some Big Orange Cable, but you want to put some connectors on it. Oh wait, you don't have the the $2000 crimper for the connector you want to use just this one time? 


Steps for Ordering

Follow these steps to spec and order your Big Orange Cable high-voltage cable assembly. 

1. Design

We'll need information about what you're trying to connect. To get started, we'd like to know things such as:

  • What components are you trying to connect? 
  • Do you already know what terminals you need on each end?
  • Approximately how long of a cable do you want? 
  • Are you interested in having the cable wrapped in our Big Orange conduit?
  • Maximum current rating needed?
  • Continuous or peak current application?
  • Space constraints and bend radius limitations?

2. Contact to Quote

Take all the info collected in Step 1 and send it us an email to info@bigorangecable.com or Contact Us. We'll reply with any questions we have to fill in the gaps or adjust the design where necessary to ensure proper fit and function. If your design is particularly complex, we may need to agree on the necessary engineering or design fees to complete your project. 

A note about lead times: We stock a few common connectors, but many we have to bring in. We'll let you know how long that will take along with your invoice. Once we have the terminals, most assemblies can be fabricated, tested, and shipped in a week. 

3. Order

We'll send you an online invoice and get to work ordering parts, fabricating, and testing your assembly. 

4. Install

You're cable assembly comes pre-tested for installation into your project. If you run into any issue or questions about your assembly, reach back out to us and we'll do our best to help resolve the issue quickly.  

Notes & Tips for ordering your custom assembly

  • Sometimes it just won't work. Cable and terminal in-compatibility and validation may impair our ability to design an assembly for you. We'll let you know this ASAP after you contact us. 
  • That being said, contact us early! If you haven't already purchased components, we can often help steer you towards components that are easy to connect together, saving you time, money, and effort in your next EV build. Even if the cable you need is months away, we want to hear from you now...
  • More information is nice, but it's not required. Tell us what you know now to get your project kicked off today. 
  • Measuring your desired cable length can easily be done with a piece of rope or cord. 
  • Where available, we may be able to spec a right angle or straight terminal to reduce cable bends in your design.
  • Designing a validated cable assembly often takes time and engineering effort. Although we do our best to avoid these costs, Big Orange Cable may need to charge an explicit fee to cover this costs as a result of your project.  

More Information about our Custom Assemblies

We've partnered with Carterm Design to offer HV cable design services. They are focused on automotive electronics consulting, design, and prototype assemblies.

Carterm also designs and build low voltage assemblies, so if you need help wiring up your inverter to the rest of your wire harness, they can help with that too. 

You can reach out to Carterm here: info@carterm.design