With work and life getting in the way, the free time I have to dedicate to boat projects is limited. Therefore my battery/alternator repair and upgrade
is still ongoing. I have installed new house batteries, but the alternator was still giving me fits, so I have replaced it. But there is an odd problem, I was hoping to get your help on.
The old alternator was a Delco Remy 10-SI with a three blade harness, similar to this one:
The new alternator is a 12-SI, which is promised to be an in-place upgrade. And it is, for the most part, except for the wiring. The new alternator does not have a wiring harness, but rather has attached wires with bullet type connectors similar to the male one shown here:
This seems like a bad connector for the high-vibration, high amperage environment in and around an alternator.
"No problem", I think to myself "I'll just splice the wires with heat shrink butt connectors". But once I crawl into my engine room to do so, the wires going into the old clip state "do not cut, do not splice".
Replacing the entire wiring harness looks to be very difficult, as the wires go into conduit snaked around the engine, and the wires inside the conduit are ziptied. Further, I can't find a replacement alternator that uses the three-wire connector.