Cables for 200 Amp Alternator
 

Hey Bros and Brosettes
I got a 200 amp alternator on its way. The seller recomended 4 gauge wire with a multimeter fuse. Looking for some guidance as to which wires I should replace (battery too?), where I can get them or how to make them on my own. Woke up this morning to the realization that I had lost the spacer from behind the fan on the pulley of the alt making it loose as a goose!

Look forward to hearing from you guys!

This guy is a member on this forum and from what I have ready does a real nice job. I emailed him a few weeks ago and got an "away" auto reply but then he emailed me pretty quick and said he still makes them. I have yet to order mine but plan on it real soon.

I am sure someone will come on here and tell you who he is. I emailed him through his website.

http://www.kelleyswip.com/

5-90 on the forum, my understanding is he busy so not as active as he once was. Great kit. Email him and he will set you up.

I prefer to make up my own.

Wire and lugs can be found a NAPA and the heat shrink tubing at Lowes.

I drill a 1/8" hole in the face of my copper lug and fill with solder, use flux. Much better than crimp on lugs.

Attachment 313880

5-90's kits are very well made and in proper sizing for the amp of the alt and they are a complete kit with fuse and directions. Quality materials and labor means a lot.

For 200 amp I would do 2 gauge cables... I made my own, I went to my local welding supply store, bought 20 feet and ended up using only 16 feet in total.

I bought copper lugs from eBay and crimped them on, put some tape on the ends and heat shrunk tubing on them.

Hey guys,
Thanks for all the good insight. I decided to go with:http://custombatterycables.com/appli...kee_cables.htm

I got their 40/45 kit with terminal covers and a 16 in. alternator cable that comes with a fusible link.

That isn't what you need for a 200 amp setup.....but stick it on and find out.

Can you elaborate? What would you recommend? The alternator shop I purchased it from recommended 4 gauge wire with an in line fuse.
Thanks for the input.

You've not stated what your needs are here......what you running to consume power......

Use a little common sense.

Baring a wench......or other........

If you were to run every accessory you have.....4 off road lights, AC, Efan, head unit with amp, headlights, ......etc......... you may well be near or in excess of 120 amps. A 90 amp alt could never keep up with that load. Now you will install a 200 amp alt that in theory should keep up with your need and still keep the battery charged.



If you are to run a wench........

I'd use a two battery set up that are isolated yet can be charged by the same alt. There are some interesting 'self recovery' write-ups you can find on the net.
Then yes, I would suggest using 2 gauge fine strand cable.

Otherwise your 4 gauge wire will be sufficient.

The battery terminal is just a cheap stock one and what you want is a high quality Marine style with a wing nut setup on the stud so acc's can be added/removed easy.


The wire is to small to be effective if you ever plan to have off road lights, winch at the least 2 ga. is needed. I have had to use my lights (4 sets of Hellas) and winch a 9.5k at night for some long pulls and even they get quite warm also the electric fan runs when it hot and I only have a 160 amp alt.

Should've went with 5-90s kit, he would've got you setup.

www.kelleyswip.com

Thanks for all the good input. I have gotten in touch with 5-90 and I am getting my alternator wiring from him and possibly everything else. Thanks again :notworthy:for all the input, it's helped me a lot.

i have the 1awg kit from 5-90 with my 220amp alternator

happy with the purchase

X 1xxxx quality all the way.