Originally Posted by Mainer
If you are creating a custom cord, a cheaper solution may be to use 2/2/4 Aluminum URD ($1.18 a foot) or 2/2/2/4 Aluminum SER ($1.50 a foot), current price at Lowes, less with Veterans discount, HD may have it also. It's good for 166 amps, has less resistance (voltage drop). Copper is ridiculously high.
Use cheap 60 amp boxes and breakers or cheaper 30 amp disconnects at either end for space to connect short 10/3 SJOOW copper to NEMA TT-30 male/female ends.
Originally Posted by cvin
This is good info, thank you
No disrespect to Mainer..I would urge you to stay away from aluminum wire for this application..it’s best used by electricians not homeowners.
You need the knowledge and skill set to work with aluminum wire to safely make connections..
You have to go to a heavier gauge wire in aluminum vs copper..
6 gauge copper equates to 4 gauge aluminum.
Aluminum wire expands and contracts due to heat at a different rate then copper therefore you need very secure connections that do not get moved around a lot like what would happen with an extension cord.
The plug ends your using may not be rated for aluminum conductors
The plug ends probably will not fit the larger diameter aluminum wire
More fires and burned up connections happen with aluminum wire used in the wrong application.
You cannot join aluminum and copper wire without very specific connectors and practices.
Even “simple” l things like stripping the wire has to be done carefully…you can easily knick the wire causing it to break when you make the connection.
I would only use it for service entrance cable for a breaker panel with secure connection points.
I’m sure some electricians use aluminum wire for certain applications but IMO this isn’t one of them