Originally Posted by RV7A Flyer
These are lovely wire runs and supports and all, BUT...the problem here is not, I think, with the wire run. It's with the *bend* in the wire to take it to the terminal post. The large, stiff wire wants to unbend into a straight run, thus putting stress on the crimped connecter, ultimately leading to a break (or some number of strands break, which then leads to heating in the remaining ones, etc.). At least, that's my guess, based on what I've seen on friends' RVs with the same wires and runs.
OK. Probably should have mentioned this in my first post.
1: The fat wire running to the starter with the 90 degree bend in it was pre-bent prior to install. If the starter is removed the 90 degree bend stays put. The #2 tefzel does not want to spring back.
2: The smaller wire to the back of the alternator (unfortunately no photo showing the wire lug) comes in the the back of the alternator at approx a 30 degree angle, down from the fore/aft run to the alternator output post. The terminal lug has a corresponding bend so the lug fits on the output post without straining the crimp connection.
Bottom line is this: the wires need to come off the lug end aimed in the direction they need to run. Otherwise, I agree, the wire/lug crimp area will be forced into position and be under stress. I have found it acceptable to bend the lug (if required) up to 90 degrees to get the wire pointed where it needs to go. Just don't try to straighten the lug out again if the wire routing changes during build or in the future......re-terminate the wire end instead.