New Alternator Wiring Upgrade Configuration

[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 the kind shown above 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) 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.

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

I used the 5/16" at the alternator connection, with just a little filing around the outside to fit. The offset allows the hug to seat into the alternator 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 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.

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

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[Chuckls]

The ring terminals work just fine for me! But thanks for the clarification. I plan on redoing it in a month or so with those.

Thanks for your help!

[Gamesy]

i used lugs the whole way through, napa had them in difference hold dia

[WYOSVX]

Just adding my SVX to the list with this mod, minus the alternator itself. I was working on something else and found my battery was dying. Went to replace and decided to upgrade to an Optima and that snowballed. I found my ground wire slightly short and didn't want to splice on an extension so:
Replaced ground wire from rear of motor, replaced power wire from starter, alternator wires as in this thread mod, battery hold down.
I don't really like shiny polished metal but this was the third hold down I bought and didn't want to return another one. It, actually, looks okay for what I thought would be too blingy.
Major thanks to Svxcess for detailed information and patient assistance via messages. My results aren't quite as pretty but not bad; it's a bit tidier than stock as the rewiring of the wiring harness to rear of motor allowed me to tuck the wires tightly to the top of the frame.