Best decision
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From: Denver, NC
Best decision
I must say very informative write up in The How to Safely Choose The Right Wire Size and Type thread. It pretty much answered all my questions. However, I still have a couple. I plan to swap my alternator to a 3G 130AMP. It is a OEM alternator in the 1981 Ford Bronco 4.9L. I am going to run rock lights, 2 Aux Lights, and a wench. So hence the swap. Finally, my question is I have 4/0AWG wire that I have acquired over the years. Two 45" strands with ends already on them. I was going to use one from the starter to the solenoid and one for the ground from the chassis to the neg post on the battery because that is the only places the length will work for me without cutting. Then a 2 gauge wire from the alternator to the battery side the solenoid fused with a 175 Mega fuse. Then hook it to the battery with another 2 gauge wire. First is the 4/0 wire doing me any good at those location? Also, would it be worth finding something that would cut and crimp the 4/0 wire to do everything?
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Joined: Jan 2001
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From: Virginia
You need to think about your power hogs, and the wire needs to be sized accordingly.
Your power hogs will be the starter, the winch and possibly your lights.
"I was going to use one from the starter to the solenoid" The factory wire is big enough here, since you are not upgrading or changing the starter. Plus, you are not upgrading the wire from the bat + to the solenoid, so this new wire won't be doing much.
"and one for the ground from the chassis to the neg post on the battery" This will only improve any loads tied to the chassis. The starter is bolted to the engine, so it will not see this improved chassis ground unless you make a jumper from the chassis to the engine block, since the engine/tranny/driveline is mounted in rubber bushings and mounts. The factory ground wire usually ran from the bat neg, to a clamp on the chassis that clamped around a stripped part of the cable, and then over to the engine block to supply the starter a good return path. I would keep the factory ground the way it is, and if you plan on grounding your winch to the frame, then go ahead and mount your new heavy wire from the bat neg to the frame along with the factory ground wire. That will give you a good return path for the winch.
Your power hogs will be the starter, the winch and possibly your lights.
"I was going to use one from the starter to the solenoid" The factory wire is big enough here, since you are not upgrading or changing the starter. Plus, you are not upgrading the wire from the bat + to the solenoid, so this new wire won't be doing much.
"and one for the ground from the chassis to the neg post on the battery" This will only improve any loads tied to the chassis. The starter is bolted to the engine, so it will not see this improved chassis ground unless you make a jumper from the chassis to the engine block, since the engine/tranny/driveline is mounted in rubber bushings and mounts. The factory ground wire usually ran from the bat neg, to a clamp on the chassis that clamped around a stripped part of the cable, and then over to the engine block to supply the starter a good return path. I would keep the factory ground the way it is, and if you plan on grounding your winch to the frame, then go ahead and mount your new heavy wire from the bat neg to the frame along with the factory ground wire. That will give you a good return path for the winch.
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