Original wiring capability

Ohm's law is actually shown as I*R=E (I=current, R=resistance, E=potential or volts) Example: a 1amp load at 12V has a resistance of 12 ohms. 1a x 12ohms = 12v. In our starter example we assumed a 400 amp at 6 volts. If we assume a constant load, then the starter has an internal resistance of 6v/400a=0.15ohms. <Caution - this example is oversimplified, the current draw and the internal resistance of motors (such as starters) and other devices can vary a great deal based on the load placed on the device. If you've ever seen a starter bench tested you realize that a free spinning motor draws far less current than one at full load. In fact, an electric motor, if unprotected and loaded so greatly that it can not turn, will draw a current beyond the design of the motor and shortly release its magic smoke!> Greg's 400w stadium/trail light system, as he stated draws roughly 28.5 amps at 14v. However, to more easily determine the resistance of each light lets look at them individually. 400w/4=100w. 100w/14v=7.2a. 14v/7.2a=2ohms rounded.

 

Back OT, in answer to Bill's original question I suggest the same as Greg did. I upgraded to a 63amp delco about 5 years ago. At the same time I changed the wire from the armature terminal to the starter terminal to 8 guage. No modification to anything else. No problems.

 

Will, so someone taught you about that magic smoke huh?? I learned about it in college from a Professor named Greer. Funny guy. You can never seem to put that smoke back in, huh?!
Prof Greer was a smart guy, he was watching me load test the starter on my small block Chevy, and just by listening to the sound he said over my shoulder, "drawing a little high?" I was like "yeah matter a fact about 100 amps high" He says "you go 4 wheeling a lot?" me "yep" He said grease the bushing on the end plate of the starter. I was skeptical, but just adding a light film of grease to that rear bushing dropped the reading 100 amps right into the proper range and made the starter turn noticeably faster. Like I said, smart guy.