Upgrading alternator on 1991 HDJ81 (1 Viewer)

[OutInCreation]

I'm upgrading the original 80 Amp alternator to a DC Power, Inc. 180 Amp and wanted some feedback on upgrading the cables and anything else necessary. So anyone who's done this before please share your experience. My research is saying go with 2 AWG for short runs, under 6 feet, or 0 AWG for longer and some say just use 0 AWG all around just to be on the safe side. I'm thinking replace all the cables including going to the starter and distribution block (I think that's what it's called) using copper welding cable. Also, I'm sure I need to replace the fusible link with a higher amp one (200A or 250A??). Any thoughts or suggestions would be much appreciated including any suppliers you've used. If you've done this and know exact how much cable to order and number and sizes of lugs, that would make it so much easier.

 

[Eurasiaoverland]

Which cables do you want to upgrade and why? What do you have that needs such a large current?

Fuses, or fusible links are there to protect the components in a circuit. If you upgrade them to well beyond the current carrying capacity of the components in a circuit, what is now your fuse?

On a 60 at least, there is no fuse for the main starter supply cable.