Need to replace my alternator wire

[RadioRental]

The + is corroded near the alternator. Questions;

(1) what's the recommended awg for this?.. 4 or 6?
(2)what length do I need roughly?
(3) and do I need to go bigger than 4 if I plan to do an aux battery at some point or does it not make a difference?

thanks in advance!
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'87 2.1. 125K 4spd Not rebuilt "Red Dwarf"

[Alaric.H]

I would do 4 awg

[PDXWesty]

With the short distance between the two points, a 6ga is more than adequate to carry the full 90 amps with minimal voltage drop. Two 8ga would also be sufficient. The problem with larger wire is finding the right size lugs that will fit the posts at both ends. 4ga lugs are huge and may not fit where you need them too.
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89 Westy 2.1 Auto

[dubbified]

I found mine to be seriously damaged, and it didnt stop there.

ALso found the primary battery to Alternator wire to be corroded severly.

I went to Interstate Battery, had them fabricate 2 ga and relocated the battery to the rear seat.

[RadioRental]

thanks guys! I think I'll go with 6gauge if it's good enough.

12' should be enough, right? I'm a space cadet with it comes to mentally figuring out lengths of stuff. I'm happy to overshoot here as I'll then have leftover for the aux setup.

cheers
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'87 2.1. 125K 4spd Not rebuilt "Red Dwarf"

[PDXWesty]

A 6 ga wire is rated up to 120 amps and a 4 ga is rated up to 160 amps. Bigger wire is always better with DC voltage, but there is no need to go overboard. If I remember when I did mine, it's less than 3' between the alternator and starter. You should only see about a 1-2% voltage drop with the 6ga wire at 90 amps and 3' long.
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89 Westy 2.1 Auto

[RadioRental]

[PDXWesty]

The alternator only runs to the starter. The main battery cable runs from the starter to the battery up front. That is a much bigger wire, like a 4-ought (0000). If that is bad, you need to have a battery shop make you a new one the propper length. They often corrode inside the sheathing which is hard to detect. Also make sure your ground wire and connection inside the battery box is in good condition and clean. That's as important as the positive cable.
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89 Westy 2.1 Auto

[RadioRental]

[presslab]

Can you just trim the end of the wire and solder/crimp a new terminal on there?

A car stereo shop will have larger gauge wires. For really big wires check out a welding supply store. Home Depot and the like sometimes carry large gauge stranded wires for automotive use.

My alternator puts out 200 amps and I have #1/0 wire, so I'm no help here. Bigger wire won't hurt, a #6 wire will drop 0.1 volt from alternator to starter. Your battery will charge faster with the larger wire.

I believe the wire from starter to battery on 86-91 is #2/0 AWG.
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1986 Vanagon Westfalia EJ25
1988 Subaru GL-10 EJ20G --- 2000 Honda XR650L
2010 Titus El Guapo --- 2011 On-One 456 Ti

[RadioRental]

[Californio]

Van Cafe sells these. The easy way.