Alternator BAT Wire Gauge

[samblnc]

Y’all I have a 1973 Chevy with SBC 350. Cleaning up a rusty alternator BAT terminal stud and realizing the red wire coming out of the alternator may be 12 gauge. It has 19 strands and about 2.1mm bundle diameter. Should this be thicker like 8 gauge?

I previously had a bad connection there and the old wire was falling off at the terminal, and I guess arcing which caused fusible link to melt (fixed + new alternator). Not sure if undersized BAT wire could have contributed.

 

[Matt69olds]

The wire size needed depends on the current and distance. For a stripped down truck with a 42 amp alternator, a 10-12 charge wire is probably adequate. If the alternator is higher capacity, then a 8 gauge would be a good idea.

 

[Maxwellvis]

I've used 6GA welding wire when I've made new charge cables.
Lots of strands, good for bigger alt (and bigger stereo that sucks the juice faster/harder), and good wire that'll last a good long time.
Overkill 0GA welding wire for main bat. POS and NEG as well.

 

[Radiohead]

Overkill 0GA welding wire for main bat. POS and NEG as well.

Not overkill, just good engineering sense. No problem with oversized components in this circuit. Besides, good welding cable is more pliable which makes routing better.

Thats how I roll.

 

[Ricko1966]

Y’all I have a 1973 Chevy with SBC 350. Cleaning up a rusty alternator BAT terminal stud and realizing the red wire coming out of the alternator may be 12 gauge. It has 19 strands and about 2.1mm bundle diameter. Should this be thicker like 8 gauge?

I previously had a bad connection there and the old wire was falling off at the terminal, and I guess arcing which caused fusible link to melt (fixed + new alternator). Not sure if undersized BAT wire could have contributed.

That wire isn't undersized. They didn't use a large wire,new.

 

[75gmck25]

On my ‘75 the original alternator charge wire for a 63 amp alternator is 10 gauge with a 14 gauge fusible link.

 

[edgephoto]

I am restoring my 1987 V3500. I had new battery, charging and ground cables made by CE Auto Electric. Way nicer than any universal stuff you get at NAPA, O'Reilly's etc. Price was not much more and they fit perfect and look great. They use welding cable. It is very flexible.

Click here to get to their website.

 

[ma3600vz]

ofc or 99% copper absolutely no cca junk

 

[Maxwellvis]

Here's my Dad's thread about building these DIY style at home.

https://www.gmsquarebody.com/threads/diy-battery-cables.23014/

We now use a hydraulic crimper from HF most of the time for simplicity and speed, but either method works great.
Using the heat shrink you can get online with the glue inside is also good, helps keep the elements out better.
The VW set he made is still on my car to this day (very easily 15+ years old) with no crustiness showing, as well as the set I made for his truck.