Step 5

Now it was time to address the wiring. Since our 60-amp alternator could potentially melt the OEM 12-gauge alternator wiring, we made up a new main charging wire using 10-gauge wire along with a 14-gauge fusible link. As a rule of thumb, a fusible link should be four gauge numbers smaller than the wiring it is protecting. We stuck to the factory color code–brown in this case.

Step 6

We also made up a subharness for the exciter circuit and the charging light. These subharnesses vary from alternator to alternator, so it’s important to do your research. In our case, we used a schematic provided by Gustafson Specialty. We made up the 16-gauge wiring using the Lucas color code–brown with a yellow tracer.

Step 7

We connected the OEM charging wires to the externally mounted starter solenoid, which is the main wiring junction from the battery. We then removed the OEM wiring from this junction and wired in our new main charging wire.

Step 8

The final installation looks stock. Since we took the time to tackle each step correctly, we now have a safe, long-lasting solution that uses the factory belt.

Sources

Eclectic Motorworks
eclecticmotorworks.com

Gustafson Specialty Products
gustafsonspecialty.com

Moss Motors
mossmotors.com