Female Spade Connectors at the Relay for Alt Plug? Options

[Literati914]

I removed my chewed up 3-wire plastic plug at the relay board where the Alternator plugs in. I replace the three spades with modern copper spades - but they have no locking tabs (so I can not use the plastic plug). I thought it would be fine without the plug .. but the wires feel a little loose plugged in separately. So I want to ad a replacement 3-wire plug at the relay board. Anyone know what size the lock tab female spade connector are? I see that belmetric has 6.3, but I'm thinking they may need to be bigger..?

[Arkady]

I'm sure some on the forum have this information from either repairing or building this part of the harness.

If your alternator wires are already cut and without terminals, the wire gauge can be found by stripping an end and carefully measuring the conductor's diameter. (Be careful to not compress the stranded wire conductor.)
Or, there are measuring tools to help with the determination of the wire gauge. Any electrical supply store will have one of these. Typically, these have labeled holes of the proper size so you can insert the stripped conductor end and find the size. (The first web site shows one of these tools.)

Here's some wire gauge information:

https://www.electricaltechnology.org/2022/0...city-table.html

https://www.rapidtables.com/calc/wire/wire-gauge-chart.html

The conductors are sized to safely carry the electrical amperage without exceeding the wire's temperature rating.

The insulation is constructed and sized to prevent a spark from passing through it and finding its way to ground.

Think of electricity going through a wire as water going through a pipe. Voltage is the same as water pressure and amperage is the same as the volume of water passing through.

Push too much water volume through a pipe and the resistance to flow increases and if its being pushed by a pump, the pumps motor will heat up. Push too much current (amperage) through a wire and the resistance to electricity flow will increase and the conductor will heat up.

Push too much water pressure for the pipe and it ruptures and the water sprays out. Run too much voltage for the insulation and electricity finds the weak spot and a spark jumps through.

The previous explanation is getting into the weeds a bit, but may be helpful in understanding the 'how and why' of wire sizing.