Battery Cable Temperature

[barsss]

Last week my wife and 4 year old were going to go on a cart ride. I was setting in the recliner watching golf and my little girl came in and said mommy said the golf cart battery is dead. I knew this was not true but did not know what was going on. Went out and sure enough there was no power to cart. Pulled seat up and was not happy at what I saw. The negitive post on one battery had melted down to where there was a hole in the battery. The threated post was just sitting there with no lead holding it in place. I had to tell them no ride tonight.

Monday afternoon took battery to a battery only shop and they said scrap it and get a new one. Checked voltage on battery and it was still good. Did some research and found the link below where Rabbitreborn does repair and thought I would give it a try.

http://www.buggiesgonewild.com/elect...-repair-2.html

Only problem was hole in battery. Got the parts from lowe's to do the post repair and went o Auto Zone and bought the red high temperature silicone they sell.

Drilled a 3/16 inch hole in center of battery post deep enough to screw the hanger bolt down so that the bolt threads are the only thing showing. Put two nuts on it and drove it in with my dewalt 1/4 impact driver. Then I filled the whole in battery with a lot of the high temp silicone. Took about 3 or 4 days to dry all the way through.

Works great now only thing I can figure is that I had a bad wire, one end was discolored and hard to bend. I replaced the wire with a new one.

I have 4 gauge wires, Alltrax 400 amp controller, stock motor, 2009 Trojan T105 Batteries.

My question is after driving it last night i felt all the wires and they were really hot. What temperature should the wires \ battery post be? I have access to a laser temp gun. Any help to keep this from happening would be greatly appreciated. Was thinking about going to a 2 gauge cable set.

Thanks to Rabbitreborn for the repair idea!