As if a 3600 degree potentiometer on the dashboard to control voltage is not overkill enough, Overkill can take many forms.
This is a standard Home Despot 10-12awg ring terminal with the yellow nylon/plastic insulation removed. I decided to try and get some insulation inside the crimp since there was some room with 12awg. I tapered the insulation so it would fit.
Really digging the 'amazing goop', here used as strain relief on the Pot solder connections. The white portion is where the goop when over the masking tape. I can cut that off cleanly.
This is a '6'awg die crimp on my HFT hydraulic crimper, the first model with the black undersized dies. It is Just a little too small for a 10-12 crimp.
Amazing how much more comfortable I am with soldering now compared to a year ago.
Before crimping, copper stranding and ring terminal cleaned with 91% IPA. Base of wires next to insulation got a drop of DeOxit shield. then crimped, cleaned again and soldered to cover the stranding.
-10awg goes the few inches from one alternator field terminal to ground
12awg for the battery + always on. Wired this to AlT(+) stud
12awg for fieldwire, wired to one alternator field wire terminal.
10awg for ground from transpo540HD to alternator ground stud
A 6 foot long K type thermocouple is run inside the new Vr harness and sensor tip is thermal epoxied to the Stator exterior prepped and degreased beforehand.
A 14 awg switched lead runs back to a factory switched hot. It is Only on with engine running, not with ignition turned to just 'on'.
The rather extreme temperature of the 'trick the ECM resistor' is dismaying. I wonder if something inside my engine computer is now getting significantly hotter because of it.
I thermal epoxied it to a larger aluminum finned Heatsink that Westend sent me a while back.
The 12 awg runs from resistor, about 10 inches to the molded connectors field terminals
The red electrical tape below resistor is the Feed to the 30 amp 1/2/both/off battery switch common stud in back. Plenty of chafe protection on resistor wires where they contact heatsink.
