Is it just standard wire? Traditionally I thought fusible links used a different insulation to prevent melting and fires if the fusible link did it's job.
Another quarantine chore (battery cables)
- Thread starter Flivver250
- Start date
Is it just standard wire? Traditionally I thought fusible links used a different insulation to prevent melting and fires if the fusible link did it's job.
I had some cables made, #2 welding cable, that I was going to use for my winch but ended up using the cable that came with the winch so I would like to use the welding cable to do "the big three". What size and length of fusible link should I use? 4ga or 6ga? Or should I use a smaller ga cable for the alternator therefore a smaller ga fusible link?
They are different than typical wire. This is so that the wire inside the insulation burns without the insulation melting. That way it doesn't burn through the insulation and short to the fender.
I'm pretty sure marine wiring would meet this spec, but double check me before going that route.
I bought mine from mine from Custom Battery Cables. The quality was very good. A little pricey but hey a Jeep is a hole in your driveway that you throw money into. Stole that from the boat guys.
Sorry I forgot to mention fusible links have a special insulation over them.
You’re a glutton for punishment aren’t you?!
Seeing that I stripped and cut that perfectly functioning Jeep apart 3 years after that picture, managed to put it back together, and somehow picked up another Jeep along the way...? I vote yes. Thankfully the boat still floats.
You can if it is designed correctly by someone who knows what they are doing. The problem is the regulator takes a few seconds to get the alternator leveled out to the correct amperage. You can hear that sometimes on start up when the belt squeals. That is a high load at the alternator pulley which can also be an amperage spike which can take out a fuse.
Is the alternator installed in the 01 TJ 4.0L any different than the one in the '98 XJ 4.0L ?
Almost 20 years ago I replaced the stock alternator in a '98 XJ with a 137A from a '98 GC, built a set of 2 Ga fine stranded +/- cables and fusion connectors with a 6 Ga charge wire and a 125A 32V bus fuse installed inline to the PDC. This setup worked so well there were numerous members on NAXJA that copied my setup.
This fuse is of a similar design; so I was just wondering.
They really can be. Mine is just a 12ft aluminum row boat I got cheap with the trailer for $200 that I mounted a 15hp 2 stroke Yamaha on. Fun, goes fast, but hardly a money pit.
That's the kinda boat I'm looking for now. I went from that pig in the picture to an inflatable kayak. One is too big, the other too small. Both fun for intended purpose though. That 12-14 foot aluminum boat is just perfect for the kind of fishing I like to do.
Can anyone verify the stock battery wire gauge sizes?
Best I can tell
Negative to block - 4 gauge
Negative to body - 4 gauge
Positive to Starter - 4 gauge
Positive to Fuse Block - 6 gauge
I'm only going to replace the battery connectors on both of my TJs with those "Military Style" Terminals for now, and want to be sure I get the right lugs to crimp on. I know for that style of connector I need a 3/8" hole but just want to be sure of the barrel size.
Best I can tell
Negative to block - 4 gauge
Negative to body - 4 gauge
Positive to Starter - 4 gauge
Positive to Fuse Block - 6 gauge
I'm only going to replace the battery connectors on both of my TJs with those "Military Style" Terminals for now, and want to be sure I get the right lugs to crimp on. I know for that style of connector I need a 3/8" hole but just want to be sure of the barrel size.
I used 2 gauge to the starter and block. I think the originals were 4 gauge. I kept the funny connector from the battery the same, but ran a new cable to the alternator. The alternator cable I will probably replace with a pre-made fusable link at some point soon. Get good pure copper cables if you end up replacing any of them.
I keep kits like this in inventory. Make sure you use a good crimper and make it pretty with shrink tubing.
https://www.amazon.com/gp/product/B07MJB21XR/?tag=wranglerorg-20
I keep kits like this in inventory. Make sure you use a good crimper and make it pretty with shrink tubing.
https://www.amazon.com/gp/product/B07MJB21XR/?tag=wranglerorg-20
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