How To Fix Speaker Wire Melting On the Subwoofer Terminal Cup


If the speaker wires connected to the terminals cups on your subwoofer box are melted, the possible cause can be of excessive resistance. The lower the electrical resistance, the lower ohm impedance created from the voice coils, the more power the car amplifier is going to push out. This allows more heat being creating, as a stronger current is passing down the speaker cables. You will need to resolve this car audio problem before you replace the current melted terminal cup with a brand new part or else the same issue is going to take place and be a reoccurring process.

1) Replace the speaker wire for a thicker size. Chances are the speaker wire melted because the wire gauge thickness was insufficient for the amount of power you are sending to your subwoofers. So just to be on the safe side, its always best to get the thickest wire size even if you don't need it. Personally, I always recommend 12 gauge wire for both low and high power car audio system installs for the best sound quality and durability. 

2) Ensure that all the connections are firmly secure. Be certain that the speaker wires that connect directly to the subwoofers inside the box are securely attached onto the back of the terminal cup and on the terminals attached on the subwoofer basket. Also ensure that the speaker wire is nicely fitted tight into the terminal posts outside the subwoofer enclosure and into the car amplifier itself. This is because loose connections can cause large amounts of current to not get passed on properly resulting in the anything close by that is plastic to become melted.

3) If you are running some serious power consider using bolts and washers instead of plastic speaker terminals cups. So basically you will need to fit two regular brass bolts drilling them into the box and connect your speaker wire to the car amplifier through them providing the best direct connection available. This works the best for large subwoofer systems that are more than 5000 watts rms. Since that amount of power would be way too much for any cheap or expensive terminal cup to handle regardless of where it has been purchased from and what make it is.
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