copper-clad aluminum (CCA) wire Vs all copper for 6V systems

[Lon Jackson]

What is your experience and or recommendations for use of subject wire for our old cars.
If you think your lights may pull 20 amps, what gauge CCA would you need Vs all copper for a 10 foot run.

[bobH]

Can't answer your question. But, why would I even consider it? I had some of that stuff come with a trailer light kit. Corroded away, didn't even last through one season. Sorry, I'm being negative on this. Hopefully, someone with positive experience will counter me.

[Hitman]

Copper is the only way to go. It’s still cheap, and way more reliable. Why even consider anything else?

[fordor41]

there's a reason why it was outlawed for home construction.

[cadillac512]

Originally Posted by Lon Jackson

What is your experience and or recommendations for use of subject wire for our old cars.
If you think your lights may pull 20 amps, what gauge CCA would you need Vs all copper for a 10 foot run.

I would not use the clad wire, but as far as sizing if you have 20A load #12 wire of either variety will be needed. #14 in copper may carry it but you'll have better voltage at the bulbs with 12.



Terry

[rotorwrench]

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Aluminum wire will conduct electricity but not as well as copper on low voltages. When using any aluminum wire as a replacement for copper, it has to be several times larger gauge to carry the same amperage depending on system voltage. The only place it is still widely used is for power lines due to it's light weight and the much higher voltages involved.

At one time it was used in large aircraft for it's light weight but only in #8 gauge and larger sizes. Smaller gauge use is discouraged by the FAA. For light aircraft, it's really not needed. Tin and silver plated copper are the norm for aviation purposes. Bare copper is rarely used due to corrosion deterioration over long periods when in swampy areas of the aircraft that are exposed to moisture at times such as wheel wells or similar areas.

[ford38v8]

Originally Posted by rotorwrench

Aluminum wire will conduct electricity but not as well as copper on low voltages. When using any aluminum wire as a replacement for copper, it has to be several times larger gauge to carry the same amperage depending on system voltage. The only place it is still widely used is for power lines due to it's light weight and the much higher voltages involved.

At one time it was used in large aircraft for it's light weight but only in #8 gauge and larger sizes. Smaller gauge use is discouraged by the FAA. For light aircraft, it's really not needed. Tin and silver plated copper are the norm for aviation purposes. Bare copper is rarely usedf due to corrosion deterioration over long periods when in swampy areas of the aircraft that are exposed to moisture at times such as wheel wells or similar areas.

Tin plating is common, but I didn’t know about silver plating copper wire. Coincidentally, as I understand, silver is the only metal more conductive than copper. Anyone heard differently?

[koates]

Lon, Just inquiring why you would even consider using wire cable which does not meet the original specifications of the auto manufacturer ? Do you already own a bundle of that cheap aluminium cable ? If you do then dont use it, throw it in the scrap pile. Copper only in old 6 volt and 12 volt cars, Regards, Kevin.

[rotorwrench]

Gold is the most conductive metal but it is not practical for anything except for plating of terminal pins in cannon type plugs. Gold doesn't tarnish and with liberal use of DC4 silicon grease in the plug, it will outlast me in a dry temperature controlled environment.

This stuff is used a lot by the military for all sorts of electrical equipment from radio intercom to gun sighting and control systems plus forward looking infrared camera equipment & other systems. This is why military hardware is so expensive. It is still made to work first time every time. PTFE is one of many common types of outer insulation used on aerospace grade wire. Some of it is pretty exotic and expensive. Most of it comes only in white. They don't color code it. They print the wire code on every six inches of the wire from the start to the end of the circuit.

The TWA flight 800 that supposedly had the main fuel tank blow up on climb out of New England bound for Europe started a trend toward fail safe electrical wiring for all subsequent aircraft. It has been used in missile systems and space craft for a while but is now used industry wide. I consider this a good thing even if they were wrong about how that aircraft came to its untimely end.

[ford38v8]

Originally Posted by rotorwrench

Gold is the most conductive metal but it is not practical for anything except for plating of terminal pins in cannon type plugs. Gold doesn't tarnish and with liberal use of DC4 silicon grease in the plug, it will outlast me in a dry temperature controlled environment.

This stuff is used a lot by the military for all sorts of electrical equipment from radio intercom to gun sighting and control systems plus forward looking infrared camera equipment & other systems. This is why military hardware is so expensive. It is still made to work first time every time. PTFE is one of many common types of outer insulation used on aerospace grade wire. Some of it is pretty exotic and expensive. Most of it comes only in white. They don't color code it. They print the wire code on every six inches of the wire from the start to the end of the circuit.

The TWA flight 800 that supposedly had the main fuel tank blow up on climb out of New England bound for Europe started a trend toward fail safe electrical wiring for all subsequent aircraft. It has been used in missile systems and space craft for a while but is now used industry wide. I consider this a good thing even if they were wrong about how that aircraft came to its untimely end.

Knowing who to blame is the difference between career advancement and early retirement.