{"id":8227,"date":"2021-05-05T19:53:40","date_gmt":"2021-05-05T09:53:40","guid":{"rendered":"https:\/\/thedocaus.com\/blog\/?page_id=8227"},"modified":"2025-11-26T12:15:24","modified_gmt":"2025-11-26T01:15:24","slug":"anderson-plug-pitfalls","status":"publish","type":"page","link":"http:\/\/thedocaus.com\/blog\/?page_id=8227","title":{"rendered":"Anderson plug pitfalls"},"content":{"rendered":"\n

The Doc has been working with Anderson plugs lately. Anderson plugs are used for various 12 volt wiring in the Nissan Patrol, like supplying power to the fridge or auxiliary battery in the trailer. They look like this:<\/p>\n\n\n\n

\"Genuine<\/figure>\n\n\n\n

The new solar panel is connected to the DC to DC charger with an Anderson plug, plus the new Battery Box also has them.<\/p>\n\n\n\n

Anderson plugs come in various sizes and colours, the most common is the grey 50amp version used in cars and caravans. Anderson plugs come in various colours, with each colour only being compatible with the same colour (although black and grey of the same size are commonly compatible). The Doc is talking about the grey 50amp plugs.<\/p>\n\n\n\n

The Doc has identified a few pitfalls when buying them.<\/p>\n\n\n\n

Anderson plug verse Anderson \u201cstyle\u201d plug<\/strong>
The genuine Anderson plugs are called Anderson plugs, the third party knock offs are normally called Anderson \u201cstyle\u201d plugs. The knock offs can have a different size housing which can cause issues when plugging them into a genuine Anderson plug. They can also be of inferior quality. Lastly, the spring inside an Anderson \u201cstyle\u201d plug that holds the lug in place can be sub-standard compared to the real thing. Warning: <\/strong>knock off lugs may not fit properly into a genuine Anderson housing. The lugs will not correctly lock over the internal spring.<\/p>\n\n\n\n

Tip<\/strong>: buy the genuine item (see more below).<\/p>\n\n\n\n

Sky high pricing<\/strong>
The Doc has seen pricing as high as $40 for a genuine grey Anderson plug with the lugs. A complete Anderson plug means the housing plus two lugs (sometimes the housings and lugs are sold separately). Other colours like red (commonly used with solar), blue and yellow cost even more.<\/p>\n\n\n\n

Even third-party knock offs can be over $25 for a single Anderson plug!<\/p>\n\n\n\n

Either price is daylight robbery.<\/p>\n\n\n\n

Buy genuine Anderson plugs here<\/strong>
The Doc sources genuine Anderson plugs for about $3.50 each (including lugs in March 2023). The price can vary a little depending on how many you buy. Even Australian Direct (now called KickAss) sells a knock off for $9 each, plus postage.<\/p>\n\n\n\n

The Doc buys genuine Anderson plugs at Connector-Tech ALS\u2019 Ebay store <\/strong>here<\/strong><\/a>. Update May 2025, CTALS have closed their eBay store, you need to buy at their website<\/a>. <\/p>\n\n\n\n

Lug size varies<\/strong>
Many Anderson “style” plugs have only one size lug. We are talking of the internal size on the hollow end where the wire is crimped or soldered.<\/p>\n\n\n\n

The Doc crimps the copper wire into the lug, when using thinner wire this can cause problems when crimping.<\/p>\n\n\n\n

You can buy genuine Anderson lugs in 3 internal sizes, 6AWG<\/a>, 8AWG <\/a>or 10-12AWG<\/a>. The Doc then matches the wire size to the hollow end of the lug to get a perfect crimp.<\/p>\n\n\n\n

Tip:<\/strong> it is always a good idea to have extra lugs if you mess up a crimp or need to rewire a plug.<\/p>\n\n\n\n

You can change the Anderson plug housing<\/strong>
Anderson plugs of a given size (say 50amp) but a different colour are not generally compatible, as the housing shape is different. It is intended to stop people accidentally mixing up incompatible power systems.<\/p>\n\n\n\n

However, the lugs are the same. You can remove the lugs and wiring from say a grey Anderson plug and insert then into a spare red, blue or yellow Anderson plug of the same size.<\/p>\n\n\n\n

Tip:<\/strong> the lugs click over the spring on the inside of the housing. Get a small screw driver, press down on the spring to release the lug and pull out the wire and lug. Insert into the new housing.<\/p>\n\n\n\n

Quality copper cable<\/strong>
The other important requirement is good quality copper wire of the correct size. There is good quality copper wire made here in Australia by Tycab and Wise Owl. The Doc buys Australian made Wise Owl (made by Austech Wire & Cable<\/a>) or Tycab <\/a>copper wire \u2013 often from PX Wholesales<\/a>, Connector Tech ALS<\/a>, Tinker Wholesale<\/a>, Autoelec <\/a>or Brillante Sales<\/a>.<\/p>\n\n\n\n

Good quality copper wire can be expensive, but do it once and do it right. A failure in the power system in remote Australia can be disastrous and expensive.<\/p>\n\n\n\n

Tip:<\/strong> keep wire offcuts, as The Doc has made various adapters from offcuts, like a grey Anderson plug (general usage) to a red Anderson plug commonly used for solar panels. It is only 30cm long but allows a conversion from one type of plug to another. Another option is to make a double adapter like this one from Australian Direct:<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

Crimping tips<\/strong>
Watch this short video guide:<\/p>\n\n\n\n

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