Alternator batt post red hot

[jrichker]

http://www.stangnet.com/mustang-forums/threads/3g-alternator-install-a-how-to.646825/#post-6673702
Alternator wiring.

Alternator wiring diagram for 87-93 Mustangs.

Starter solenoid wiring 86-91 model cars.

Connect the fused 4 gauge wire to the alternator and the battery side of the starter solenoid.

Starter solenoid wiring 92-93 model cars.

 

[RangerJoe]

Late to the party. I do not like the audio cable for this application. I had a similar issue where my charging cable met my mega fuse. If the crimp is not perfect, or the wire is asked to make a sharp turn, the fine strands are easy to break. After some time these small strands break until you are left with a substantially smaller wire connection and it melts. Happened to me. Good call on the regular automotive cable.

Joe

 

[JD1964]

Put the alt in and rough wired it to do some performance tests. Tests were done at idle 700 with headlights on, AC on max (which makes elec rad fan run) and at different blower speeds.

From low to high blower speeds with AC on max and headlights on at idle here are the numbers. 13.9v, 13.2v, 12.7v, 12.4v.

At idle with AC off and headlights on - 14.3v

Everything on, I mean everything!!!, 2000rpm - 14.1v

No overheating of wiring observed. I'm happy and finalizing cable lengths and connections.

 

[JD1964]

The alternator is a DB Electrical unit. Got it on Amazon for $78. We’ll see how it holds up. It came with a spec sheet.

https://www.dbelectrical.com/alternators/automotive/ford/mustang/5-0-liter/

 

[Blown88GT]

...From low to high blower speeds with AC on max and headlights on at idle here are the numbers. 13.9v, 13.2v, 12.7v, 12.4v....

Looks like the pulley is too big. Pretty common for aftermarket 3G's.
It probably has the 2-1/2" pulley, instead of a 1-7/8"mm pulley.
This one will spin the alternator faster at idle: ASP520004
Scroll to bottom of linked page; http://autospecialties.com/ford.html

 

[JD1964]

Looks like the pulley is too big. Pretty common for aftermarket 3G's.
It probably has the 2-1/2" pulley, instead of a 1-7/8"mm pulley.
This one will spin the alternator faster at idle: ASP520004
Scroll to bottom of linked page; http://autospecialties.com/ford.html

The pulley on the old alt was 2 3/4". The pulley on the new alt is 2 3/8". So it's an improvement from before at least. If I'm idling while using AC I'll just turn the blower speed to low. The crank it up when driving again. All good in my opinion. (note > opinion)

 

[JD1964]

5 pics limit per post so see multiple posts... sorry about sideways pics

I've got it wrapped up I think. Made the cable and trimmed other wiring. Enclosed everything in conduit, taped ends, zip ties. The usual backyard tactics. Its reliable but not gonna win any show car trophy. I wasn't trying anyway. Anyway, pics are everything so here's a few with captions.


Saw this done on YouTube. Made a crimper by cutting a nut in half....here it is

Put the cable in and clamp down with vice

Heres the result. Pretty good huh?

Sweated some solder in for good measure. It sucked up a good amount

Here's the finished cable wrapped in conduit and marked with red electrical tape.

 

[JD1964]

Continued from above. There's a third post with more pics too

Here's the cable installed. Its secured to other conduit that runs under the front of the oil pan.

Here's the connection at the alternator

Here's the connections at the fuse holder (125 amp fuse) located on frame near power steering pump.

The original double #10 wires were cut off to reduce excess bundling. I'll keep this section in case its needed in future. The remaining single #10 was capped with a shrink wrap connector so it's available for future use if needed.

Here's the regulator and field wiring wrapped up in conduit.

 

[JD1964]

Made another ground cable

Connected ground cable from alternator bracket to passenger side frame

AC gets really cold on medium fan setting. Holds good voltage at idle with AC on, Burrrrrr.......

I love this cig lighter voltage reader. I have several of them and order more to give to friends, I highly recommend you get one. It gives real time running numbers. It's amazing how much movement you get from factory gauges on the foxbody mustangs. I can see how people think they have a problem when looking at the factory gauges. In reality, they are accurate but difficult to get comfortable with. The factory gauges fluctuate substantially, still be in the normal range and give you no clue where you actually are. That goes for voltage, water temp and oil pressure.

Amazon product ASIN B000EVWDU0View: https://www.amazon.com/Innova-3721-Battery-Charging-Monitor/dp/B000EVWDU0/ref=sr_1_2?ie=UTF8&qid=1531714274&sr=8-2&keywords=innova+voltage+tester

 

[Blown88GT]

My voltmeter