My Battery Always Dies - Part 5 Checking the Sizes of Wires, Why and How Previous : My Battery Always Dies - Part 4 Checking the Sizes of Fuses, Overcurrent Protection Next: My Battery Always Dies - Part 6 Sizing your Alternator Considerations Vehicle Wiring: Voltage Drop calculator for DC Wires All wires passing electricity are subject to what is called "Voltage Drop". Simply put, the more amps you push through a wire, the lower the voltage goes. The loss is due to friction in the wires basically. Voltage drop affects positive and negative wires, both AC and DC currents in a similar manner. Vehicles have some other interesting quirks involved, so we will discuss positive and negative separately. Negative Wires: The frames of our vehicles serve as the negative in the DC power circuit that powers everything in the vehicle. There is a lot of metal in the frame, so we don't really have to worry about wires all the way back to the battery, their weight, or cost. There are generally two things you should consider: 1. Install a very heavy gauge ground from the battery to the frame is absolutely NECESSARY. DOUBLE THEM UP IF IN DOUBT. The frame serves the purpose of carrying the current to the ground straps nicely. However, you need to give the frame a big wire to discharge to. Combine all the amps from all the sources possible when doing the wire calculations for the negative ground strap. 2. When doing wire calculations, count the frame as the same gauge as the wire, you don't get an advantage with the frame, just a lack of much loss. Measure the distance for the positive (red) wire, use this distance for the wire calculator. Voltage Drop calculator for DC Wires Positive Wires: Each item, be it the air conditioner, starter, or radio, usually has a unique connection to the vehicle's fuse box, and then a communal wire back to the battery from there. Some fuse boxes are easily opened, wires removed, and new thicker ones soldered in. If your upgrade is small, you may only need a new fuse (see above Fuses). However, many fuse boxes are not accessible, are pre wired, and so forth. This makes the upgrading of wires more challenging, but there is an easy way to do this. First, locate the unique outbound wire for the circuit in question and the corresponding fuse. Once the fuse and wire are isolated, remove the fuse, and clip the wire. Install a new fuse holder, and load with fuse at appropriate amperage (usually the size of the load + 20%-50%), and a wire thick enough to handle the amperage directly to the battery. Voltage Drop calculator for DC Wires Firewalls: Firewalls provide 4 critical functions as they isolate the engine compartment and the cockpit of the vehicle: safety from fire in the engine bay isolates noise of the engine keeps the cold/heat out blocks road debris To properly pass current through a firewall, install a couple pass throughs. Firewall passthroughs isolate the engine bay from the cockpit and are very easy to install. Simply drill a hole in the firewall, insert piece, (optional add washer not included), screw down other side. They provide an easy jump for positive and negative terminals, allow for insulation from engine noise and are sealable for water tight installations. Click below to see these items. Firewall Pass Throughs and Battery Box Jumper Terminals - $6.99 Firewall Pass Throughs and Battery Box Jumper Terminals - $6.99 If you find this helpful, Digg, Del.icious, blog, or drop us a line about it. BD Batteries Previous : My Battery Always Dies - Part 4 Checking the Sizes of Fuses, Overcurrent Protection Next: My Battery Always Dies - Part 6 Sizing your Alternator Considerations My Battery Always Dies - Part 1 The Reality of Accessories in the Modern Automobile My Battery Always Dies - Part 2 Scenarios Where Your Battery May Die! My Battery Always Dies - Part 3 Sizing your Battery for Your Accessories My Battery Always Dies - Part 4 Checking the Sizes of Fuses, Overcurrent Protection My Battery Always Dies - Part 5 Checking the Sizes of Wires, Why and How My Battery Always Dies - Part 6 Sizing your Alternator Considerations My Battery Always Dies - Part 7 Adding Land Based Chargers, Generators, and More! Legally: REMEMBER, ELECTRICITY HURTS, IT CAN KILL YOU. BD BATTERIES TAKES NO RESPONSIBILITY FOR YOUR ACTIONS WITH THIS INFORMATION. IF YOU AREN'T TRAINED TO WORK WITH ELECTRICITY, CALL SOMEONE WHO IS. IF YOU CHOOSE TO MEDDLE, YOU AGREE TO TAKE RESPONSIBILITY FOR YOURSELF! THIS GUIDE IS IN NO WAY A COMPLETE ELECTRICAL GUIDE, AND SHALL NOT BE PRESENTED AS SUCH IN ANY FORMAT OR FORUM. PERFORMANCE BATTERIES ARE CAPABLE OF ARC WELDING STEEL AND OTHER VERY INTERESTING THINGS INCLUDING YOUR HEART. BE CAREFUL, DON'T HURT YOURSELVES.

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