In my haste to get my car up and running, I forgot to tighten the nut on the alternator post... I had added a new 10GA wire (in addition to the "stock" 10GA), running to a separate junction block to power my fans and headlights...

I drove the car around for 30 minutes or so, and later Steve (Vrooom3440) came by and noticed that the new cable was starting to melt (the plastic sleeve on the crimp connector and the first inch+ of the insulation)... I was running my fans (up to 50A on startup, 25 Amp each), but nothing else was running on that circuit... And I didn't start both fans at the same time...

I am wondering IF the resistance (and heat) could have been higher because the wire/ connector was loose?


I have heard in years past that disconnecting a battery will cause the alternator to produce max charging current (and often burn itself out), so I am wondering if that is what might have happened...

I know I did hear some wierd noises from the alternator (I think, could have been the A/C compressor) when I turned the fans on, but with the exhaust, I couldn't really hear too well...


I still haven't checked to see if my alternator is okay (Powermaster 100 Amp)...

Thanks...

Yes, resistance and heat were higher because it was loose. The electricity having to jump between the contact points will do that. That's why everything electrical needs to be clean and tight.