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Old 03-23-08, 03:02 PM   #22 (permalink)
Photoman
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Join Date: Mar 2003
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There has been some questions as to how to do the wiring for this modification so I will post something here and some pictures, some of which will be redundant. I am not an electrical engineer so if I get something wrong please correct me.
Apologies to dial ups for the pictures.

The only wire that needs to be upgraded is the one that runs from the alternator to the positive post on the battery. If a person is running a single battery a new wire can just be run from the "B" post on the alternator through a fuse to the battery. The stock "B" terminal wire would still be connected to the alternator. Up by the battery is a plastic box marked AM1. Inside the box is a couple of large wires, one of which is the wire that comes from the stock alternator. This wire could be unbolted here or left connected as a parallel wire.
As far as wire size goes, it depends on the length of run of wire. As best I can determine with one battery in the stock location a number 4 wire should be the minimum. For dual batteries with longer runs something up to a 2/0 could be used. There are online charts for wire size and distance. Using a bigger wire size is almost always better.
Included is a picture of a some fuse connectors that would work. The holder takes fuses from 100 to 300 amp which are purchased separately. I understand the alternator should be fused at 20% over the capacity. Keep in mind the fusing is to protect the wires. So you can't put in a large fuse with a small wire or the wire will just burn up which is the thing we are trying to avoid.
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Bill
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Last edited by Photoman; 05-02-08 at 08:06 AM. Reason: Simplification and clarification
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