There's nothing wrong with running 25 mm sq cable John, when you're talking reasonably high currents such as 80 amps there's no such thing as cable that's too big

though I'm surprised that industry still use the obsolete and totally meaningless AWG (American Wire Gauge) and B&S (Brown & Sharpe) wire gauge descriptors when talking cable size. There's only one meaningful measurement of cable size and that's square millimeters, fancy that, a unit that actually conveys meaningful information and we went metric when ? 1974
Don't confuse this though with automotive wire gauge where they use a totally misleading cable size that includes the diameter of the cable
AND insulation to define cable size so that an Automotive 4mm cable is actually only 1.8 sq mm.

Talk about misleading the average punter and ripping them off when buying cable.
Considering your fuses though, what type of fuse did you use ? Normal blade fuses are way too small for this but maxi blades go up to 100 amp or so but still have quite small 'cross sectional area' contacts IMO for currents of this magnitude. HRC type fuses might be big and bulky but I'm yet to see one with burnt contacts at this current level

Codan actually recommended using this type of fuse for my HF radio.
Deano

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