Hello all,

I have read through the archives about alternator upgrades, but I have a couple of questions before I gather the materials to perform the task.

I am upgrading to a 100 amp, internally regulated, 10 SI alternator and would like to do as simple of an upgrade to the stock harness as I can get away with.

Being a novice at electrical work, I would like to purchase a kit from MAD to rewire the system, But I have tried for over a week to get a hold of him with no luck. As a plan B, I am going to use a kit from Yearone to eliminate the regulator, but I have a question about needing to beef up the wire from the alternator to the horn relay as is recommended in MAD electrical's tech area.

Do I need to upgrade this wire to at least an 8 guage wire? The only accessories that I plan on addding are a small amplifier and a headlight upgrade with dual relays. Also, can I add a terminal block near the horn relay to run these accessories from, and what would I need to do so?

If anyone else has suggestions for my upgrade please feel free to provide info, preferably with detailed diagrams as I am electrically challenged.

Thanks!

http://www.chevelles.com/showroom/data/500/medium/Alternator_wiring_harness_conversion.GIF

I added relays to power the headlights on my Toronado; I took power directly from the alternator output terminal via a fusible link and 12-gauge wire. No need for a terminal strip, just add a ring terminal to the end of the fusible link wire and attach to the output terminal. You could do the same with the power supply wire for other accessories--the stud on the alternator is plenty long enough to add a few additional ring terminals back there.

You don't need a "kit" to eliminate the external voltage regulator, you need two three-inch jumper wires. Make 'em yourself for about fifteen cents apiece.

Thanks for the info, but I was under the impression that by upgrading to a larger output alternator I would need to also upgrade the wire from it to the horn relay. I also thought that if I was going to do this I might as well add a terminal block for ease of access in the future.

What I really want to know is if I can run this new wire from the alt. to a terminal block and then from the block to the original wire which connected to the "main splice" in the harness then connects to the horn relay. I am just trying to do this as simple as possible without totally hacking into my wiring or running excess cables everywhere.

Thanks!

Thanks for the info, but I was under the impression that by upgrading to a larger output alternator I would need to also upgrade the wire from it to the horn relay.
Not if you aren't going to pull more power through the harness than the original design capacity--provided the harness is in good condition and doesn't suffer from corrosion or damaged insulation. If you're going to NOT pull the full load of the headlights from the passenger compartment; and instead you feed the headlights via relays from the alternator output terminal--you may be pulling LESS power through the original vehicle harness.


I also thought that if I was going to do this I might as well add a terminal block for ease of access in the future. What I really want to know is if I can run this new wire from the alt. to a terminal block and then from the block to the original wire which connected to the "main splice" in the harness then connects to the horn relay. I am just trying to do this as simple as possible without totally hacking into my wiring or running excess cables everywhere.

Thanks!
Sure, but I don't see the attraction when you can just connect additional loads to the back of the alternator (as long as they're properly fused or protected by fusible link, of course!) To me, the whole point of being able to dispense with the terminal block is so you DON'T have to hack the wiring.

If you see the benefit to adding a terminal block--fine. Just more places to attract corrosion if not properly maintained in my opinion.

Thanks Schurkey!

It seems much easier to do things the way you have stated. My wiring does appear to be in fairly good shape. I will probably just leave things alone and run accessories from the alt.