First I would try to get rid of the vibration. Find someone with a
helicopter balancer. You might try replacing the stiff wire with
flexible silicone jacket welding cable of the same size since this
will take much more flex before it breaks.
A small loop at the terminal will tend to distribute the flex over a
larger length and help stop the breaking where the flex is
concentrated.
Crimp terminals are better than solder in high vibration enviroments.

On Wed, 10 Dec 2003 18:47:05 GMT, "gix" wrote:

Hi,
I 'm an italian student(then excuse for my english)and i've a problem with
my alternator(120 ampere installed on a Lycoming 360);my problem is the
broken of the wire on the terminal of my alternator,the terminal is intact
but the wire result as cut.
The reason for me is the high vibraction in the zone of connection of the
terminal on the alternator and I don't know if the broken owe by the
rigidity of the wire(the size is for the positive 4 AWG and negative 6
AWG,the type of the wire is Raychem for aereonautical application)or by the
wrong crimp.
I wont ask at you that type of the terminal is indicated use in this case?(I
utilize a Amp PIDG terminal form square);exist other possibily cause?
Thank you in advance