xr4x4rs

iTrader: (5)

just wondering if anyone can advise me on what size cables i need to replace my alternator wiring and starter wiring

as my engine is going in a xr4x4 i need to make up a loom for the altrnator,

so what size wiring do i need?

what would be the advantages and disadvantages of using thicker cables for the alternator and starter?

do they need to be the same size cabling?

do the earths have to be the same size?

also im planning in running 3 amps aswell, so will be using a amp power cable proberbly 0 gauge
what i was think as if i replace my starter and alternator wiring to thicker cable then there wont be enough room on the terminal for this extra connectors,
so could i use a distribution block, like 0 gauge from batt to block,, ten my alternator and starter coming off this with what size wiring i need

earths arnt a problem as theres on a couple ill be uisng in the terminal


any advice on this would be great

i will also need the size cabling aswell to re wire the fuel pump as this will be off teh battery aswell

thanks

xr4x4rs

iTrader: (5)

btt

JjCoDeX75

Hi matey - interestingly I am doing this on mine because my wiring is just shit!!!!!

the wiring for aq cossie (2wd) is as follows;

Big cable from Alternator to the Battery.... I will prob use a 4-8 gauge cable. Prob a bit overkill, but bigger on this is better in my opinion.

The other wire is the little one, and this goes to the battery light in the dash (detects the volt drop etc). This doesnt need to be particularly large - any 12v suitable cable should do for this bit.

The earthing is done through the bolt fixings that connect it to the engine. Providing the engine is well earthed, nothing further should be needed in this regard.

If you want to be certain, provide an earth strap between one of the bolt fixings and the engine, but make sure the engine is well earthed also!

Again - starter is similar story. Two wires IIRC - little one and big one - dont remember exactly, but Think this works in same way - big wire to battery, little wire to starter relay

xr4x4rs

iTrader: (5)

thanks mate

as the cossie loom doesnt have batt wires i have to make my own

i did cut out my origianl altaernator wires red and blue, blu is not a problem as i will use this as i kept the connector still

its what size i need to do the main batt cable to it

my main cincern is do i have to have the same size earths to match

and can i run a distribution block for these cables to save me space on my battery terminal

4-8 gauge is what i was thinking of using

i know my earth points on the battery tray are going to be good as ive just welded a new tray in!

my earths will be,
battery to gearbox
battery to tray
battery to engine as it should be (i think)

but still need to know what size wire to use for the fuel pump aswell as this will be ran off the distribution bloack but fused aswell

DazC

iTrader: (1)

I might be able to make some up for you if you want. Been doing a lot of these recently but might have run out of cable.

You leave the original blue wire on for the battery warning light but make sure it's in good condition. Same with the starter signal wire. Obviously if they need a repair then use the same cable as already fitted to the car.

DazC

iTrader: (1)

I made the cables with terminals of similar size to the originals so space is still the same on the battery posts.

xr4x4rs

iTrader: (5)

DazC

thanks for the offer mate, but i would like to make it up myself, not that bad with electrics

i understand what your saying with the same size, but i was thinking if the thicker and better the cable then surely i will get a decent voltage back to the battery from alternator

i want to not lose much voltage drop as i will be running a fair few electrics in the car

DazC

iTrader: (1)

I'll see if i can get some pictures of the cables i've made up so you have an idea. I'll give you all the details tomorrow when i'm on the pc as i'm posting this on my phone!

xr4x4rs

iTrader: (5)

no worries mate

thanks

JjCoDeX75

As far as the distribution block is concerned, there is no reason not to, but think carefully about location etc etc.

The proposed earth straps locations seem right to me.

I have a 4 gauge cable running from front to rear that was for an ice system I put in long time ago that I have since removed. This goes from the front to the rear of the vehicle via a circuit breaker under the bonnet (by the battery) and into a distribution block in th eboot. I used this to provide power to my fuel pump, and used the original supply feed to power a new relay that I located in the boot. Net result.... proper supply to pump!

I would tend to agree that bigger is better for large current items such as alternator to battery and starter etc. also same applies for your amps.

Dont waste time on the small signal wires though, there is little point in oversizing these - it will simply cost more, and achieve little.

If you are particularly concerned, consider using Caps (capacitors) which provide a more stable current to your ICE install. I used one of these to great success. This prevented excess wear on the charging circuit when the car was used with engine off!

JJ

xr4x4rs

iTrader: (5)

thanls, stereo stuff is fine, as i will be using 0 gauge for the main power and 4 gauge for the amps, i may be using a cap aswell considering i want to run 3 amps

for the distribution block under the enguine bay i was going to make a plate for it to mount to so its out of the way of any water that mite get it

fuel pump is a good idea running of the block for the stereo, never thought of that

DazC

iTrader: (1)

Right. Pictures are currently unobtainable but here are the details of what I do. Don't ask me what "guage" the wires are. I don't work in american sizes so I don't know.

1 thick (40mm squared, about 12mm CSA rated at 300 amps) power cable to the starter with an 8mm flat eyelet terminal on the starter end and a 6mm flat eyelet terminal on the battery end. Wrapped in a convoluted conduit and heat shrunk end finishers over the conduit and terminal.

1 equally as thick earth from the bell housing back to the battery with 10mm flat eyelet terminal on the bell housing end and a 6mm flat eyelet terminal on the battery end. Protected as the other cable.

Battery to body earth is just the same as above but with 2 x 6mm flat eyelet terminals and 20mm squared/8mm CSA cable (rated at 140 amps).

Alternator cable is the same as above again but with an 8mm flat eyelet terminal on the alternator end and a 6mm flat eyelet terminal on the battery end. Same protection as the other cables.

With the fuel pump, I usualy mount a relay next to the battery with a fuse and run a live and earth from the battery/relay all the way to the back of the car, through the grommet in the floor, over the tank and to the pump. All protected as the other cables in conduit with heat shrunk ends. Wire used is 4mm thin wall (40 amps).

If you haven't driven the car before you change the wiring then you won't know the difference before the wiring and after wiring but I have had people say it's one of the best thing they have done to the car, others say it's made the car loads smoother/nicer to drive and others who have noticed an increase in performance!

xr4x4rs

iTrader: (5)

DazC

top man, just what i wanted to know mate thanks

once ive finished the welding im going to make a start on the wiring

much appriciated mate

JjCoDeX75

Seconded - well put!

JJ