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Chuck and Mike, I have no official diagram showing wire sizes, but as an engineer who believes in over kill and over engineering, I can tell you in generic terms what I use and recommend. Im thinking its 6 volts right??? If its 12 about the only thing I would change is maybe use 0 instead of 00 Gauge battery n starter n ground cables. Even if its overkill and over engineered, on 6 volt systems I like 00 Gauge Battery n Starter n Ground Cables. Ground to a big main frame bolt on or close to the starter versus a tin seat or battery box is another darn good idea. On the general wiring: For Generators, I use (usually red) 12 Gauge from the Gens Armature post to the Cutout Relay or Voltage Regulators GEN Terminal,,,,, ,,,,, ,,,, and from the Cutout Relay or VR's BAT terminal up to the Ammeters Load terminal,,,,, ,,,,, and from the Ammeters Supply terminal to the Battery/Starter. If an Alternator I use 10 or 8 gauge on all those wires. Likewise, I use 12 Gauge from the ammeters Load terminal over to any light or ignition or combinations switches BAT input terminals. Thats the main input power to feed any light or ignition loads, so I like it bigger gauge even then necessary. A typical load for lights n ignition may be 10 to 15 amps or so and 14 gauge would work, but I just like 12 gauge there. As far as any wiring from a light switch down to the Gens Field post (if it uses only a 2 wire cutout relay and light switch controller) 14 will suffice as thats only a few amps. 12 would, of course, work fine also if thats all you have around. MAKE SURE ANY LIGHT SWITCHES THAT CONTROL THE GENERATORS GROUND HAVE A GOOD GROUND THEMSELVES. Most lighting circuits I use 14 Gauge but again, if all you have is 12 go for it. Although 14 or even 16 Gauge will suffice fine as its only like a 4 amp load, as overkill I use 12 Gauge from the ignition switches IGN output down to the coil and from the coil to the distributor. I DESPISE VOLTAGE DROP IN MY WIRING, ESPECIALLY WHEN I ONLY HAVE 6 TO START WITH LOL If you only wanna buy one roll of wire, just use 12 on everything but the fine multi conductor type, not the stiff single core. John T Nordhoff, retired electrical engineer in Indiana
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