Correct wire size for optimal performance

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The Mad Hat Man

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Since all wires have resistance, the longer the wire, the greater the resistance. This means that for longer wiring runs you need to use a larger wire to compensate. Without getting into the actual theory, just remember that high wire resistance results in loss of voltage. This phenomenon is referred to as “voltage drop”, and for lower voltage automotive systems, the loss of 1V or even a 1/2V can be significant. On longer wire runs, plan on using a larger size wire. There are specific voltage drop calculations that depend on the wire size in use, the length of the wire, the load applied, and the voltage in use. Below is a handy chart based on these calculations for a 12 volt DC system.

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