MAJOR CLARIFICATION: Alternator wiring upgrade

[svxcess]

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I need to make a major clarification in the alternator wiring configuration installation. No changes to the actual wiring setup, just the connectors.

Questions posted and PMs I have received are mostly about problems with the connectors on the ends of the power and ground wires. Although ring terminals were not mentioned in the article, the assumption was made to use standard ring terminals like these:




I only used this kind in two places. One is where the ground cable from the NEG battery terminal connected to the horn bracket. It was more flexible and easier to install down there. The second is on the end of the ground wire which attaches to the A/C bracket.


For the 4 gauge power wire from the POS battery terminal to the alternator (and to and from the MegaFuse if added) I used 4 gauge copper battery lugs.




For the 4 gauge ground connection at the A/C bracket, I used a regular 4 gauge ring terminal (but you could use a battery lug if desired). This wire is not really carrying current, just providing the ground path.




They are solid copper and resist the tendency to heat up and are sturdy. I believe they come in 2 hole diameters, 5/16" and 3/8".

I used the 5/16" at the alternator connection, with just a little filing of the outside to fit. The offset allows the lug to seat firmly while raising the alternator wire higher. I used battery lugs at the MegaFuse connections as well.







For the 4 gauge ground connection at the A/C bracket, I used used a regular 4 gauge ring terminal (but you could use a battery lug if desired).






These battery lugs lugs are very inexpensive and can be found at most auto parts stores or battery shops. Buy 4 of each size to be sure.


I am sorry for the confusion, I have done so many modifications over the years, I neglected to mention this change. I thought the photos would be enough. Unlike ring terminals, the battery lugs are designed to efficiently pass high currents and were sturdy enough to be trimmed in size without sacrificing surface area and strength.

Sorry for any confusion. I will take better photos of EACH connection and add it to the published upgrade.

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