Burnt wire... how did this happen?
 

Take a look at the pic. How in the hell did this happen? How do I fix it? I will run out to the truck to get more info.

It looks like possibly either a poor crimp in that connector or you exceeded the current rating of the connector. I am guessing the first. What circuit is this?

Don

I agree, solder and shrink wrap are your friend.

Appears you have a "high resistance" connection.... i.e., a crappy one -- that is acting like a toaster.

So either you're pulling too much amperage through the wiring (undersized wire for the load) -- or the connection is not capable of carrying that load. That could be due to a bad connection... or the connection is "opening up" because of the high load (think warping metal due to heat).

I would check the draw on that circuit... because the bad connection MIGHT BE your GROUND - rather than the + side of the circuit. A bad ground will be every bit as important as the actual power side! Don't over look it!

Many people don't understand the length / gauge / amp carrying charts.... those charts need to be DOUBLED on the length of the run. It's a CIRCUIT --- so if the load is 10 feet from the source -- it's calculated as 20 feet! When you use these charts correctly - the gauge of your wire will finally be ample for the load.

Good to finally meet you at OUSCI! Sorry I was really too busy to chat much.

Crappy wire...got it. This wire goes from the relay to the electric fans. I know 0, zip, ziltch, nada about wires. I will start search ing the interwebs for some info. Does anyoneknow what gauge wire might be over kill for something like this? It would be a thousand times easier to over kill this issue with a wire that better than what it should be.

David

It was great to meet you as well. I understand that you needed to tend to your high paying job on the auto-x course. Nobody waives an orange flag like you, buddy. I think you made it into some of my video as well...

It looks like you have it powered out to two diffrent leads you might want to double check and make sure you are not missing a source wire.

Many fans pull huge loads at start up. Use the correct relays and wire with solid connections.

You say FANS -- as in plural -- which says you should have RELAYS - as in PLURAL -- One relay PER FAN... and a separate power lead to each relay.

To keep that "neat" -- you'd use a distribution block. SO a wire that is capable of carrying 60 amps - to a distribution block - then power wires capable of 30 amps - one to each relay.

The ignition switch wiring carries very little amperage so can be "light" gauge -- and the one wire from the ignition can be used to switch both Relays -- ditto the "trigger wire" (from the temp switch)...

Ground both relays right near where they're mounted. If the surface is painted use a star washer between the paint/primer and the lug. I always use a flat washer between the lug and the fastener.... that way as you tighten it up - the fastener can spin against the washer rather than twisting your lug/wire. It's best to clean off the paint clear down to bare steel... but sometimes that just makes a problem. So the star washer is made to CUT into the paint and get to metal. Remember - the GROUND is just as important as the power side.