Alternator Output

A solid wire will fracture when flexed enough. A crimped stranded wire will not fracture. When you solder you are turning a stranded wire into a solid wire at the solder point.

I am not confused by the wire solder brittle break issue and have not recommended it here but for Lucas factory made terminals example and my own trim connections supported in straight runs that will last beyond my need to part them again and again. Lucas solder style or even just crimped on terminals focus the wire flex at the terminal edge so break there after a few decades vibration and handling. I left images of a few non soldered connection types so don't confuse my hobot- one in a row ways with normal bad connection suggestions. Think ahead for times primary inner cover needs removal for tranny service or drive sprocket. Another issue is placing the connections for both protection and lack of visual clutter. I don't like seeing the blade connectors nor the funky clunky Posi-Twists myself. BTW main advantage of the 3 phase sparx is low low rpm charging, where it literally shined for Peel picking my way after dark in drive way on hi beam watching for glints of deer eyes and new hazards dropped in while I was out. Relays to head lights save some juice and about only place they do as horn use is so intermittent and weak even full 14 v hardly helps it startle deer who just look around with cocked heads before they are about run over before zoom in closeness startles them. Ignitions at max output only take like 5 amps. Horn use is not so intermittent to me though as I often ride with thumb on horn button so the bouncing make it toot in static-co random ongoing alarms to calm me some but nil effect on dumb deer unfortunately.

You could also cryogenic temper the stator for less internal resistance and a few more usable watts for sock heater.

hobot said:

Go look close at the Lucas factory terminals, solder on end of wires. I was not saying to solder the charge wires connection but I'm sorely temped too with some low melt alloy i've on hand. Melts at water boil temp so hair dryer could do em on and off. Another alternative is just twist em together well and hold tiddy by heat shrink.

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What metal alloy melts a 212ºF? Electrical solder melts a 350ºF-360ºF. When you get to melting temperature below 220ºF you getting into the wax categories. Lithium and indium melt below 212º. any other elements have a melting point below 115ºF, which would make them impractical for a Norton, even in Arkansas.

Gosh what's an Ozark bumpkin to do with left over Cerro Woods metal alloy used to make tight 1/4" copper tube bends full of it?
Lookie here in case a need arises. I'm not going to solder much on Peel or Trixie so not to worry about me.
http://www.rotometals.com/Low-Melting-Alloys-s/21.htm

dynodave said:

If you discuss 3 phase that means 3 wires to carry the current.
!5 amps total out of the rectifier... means 5 amps AVERAGE per leg. or if you prefer 15 amps peak for 1/3 of the time ie 33% duty cycle per wire.

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the formula for 3 phase power is voltage X average current per leg x 1.732 (sqrt of 3) assuming a power factor of 1 so worked backwards that gives leg current of about 180/24 or 7.5 amps using an AC voltage of 14 but all three legs have a 100% duty cycle, NOT 33%, three phase does not work that way....anyway get roughly the same number

I have some aircraft solder sleeves used for shielding wires with a solder inside that melts with a heat gun. Wicked cool stuff. Aircraft standard practice in the olden days was to solder. But that is long gone now. Everything is crimped. Very little is soldered anymore. Only what can't be crimped, example switches with solder posts and light bulb holders. A properly done crimp will be the best answer. If you want a crimp weather sealed disconnect that is waterproof you can't beat this.

http://www.amphenol.co.jp/military/cata ... Splice.pdf

here is another one but still a little pricey

http://www.wirecare.com/deutsch-kits.asp

Bill,

That looks like the ticket. To be cost effective it would require more than one old Lucas wired bike. Maybe local group ownership?

BTW, I never did get back to you on Daytona. Looks like I'll be going Saturday with the cage. My thirteen year old son does not like to ride bitch and wants to go, too.

I have the deutsch stuff here and the proper Lucas bullet stuff. I will go over Wednesday to flager for the norton party but looks like that will be it for me. we have some family issues to take care of this weekend.

JimC said:

Bill,

That looks like the ticket. To be cost effective it would require more than one old Lucas wired bike. Maybe local group ownership?

BTW, I never did get back to you on Daytona. Looks like I'll be going Saturday with the cage. My thirteen year old son does not like to ride bitch and wants to go, too.

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