A few issues with my Stillen supercharger

TopgunZ

Can you put a caliper on a cable of each gen so we can vary them?

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TBatt

Unfortunately that won't work because you would be measuring the total diameter and not the wire itself. You would have to strip back the insulation to measure the wire gauge/diameter. It could also have been the crimping of the connector that is causing a problem.

A good crimping tool has an adjustment that makes sure the crimp is good. In the aerospace industry we use "coupons" which are test samples where we crimp a connector and then run it through a pull test to insure the crimp is good. The crimping tool has a ratcheting mechanism that makes the operator press the tool all of the way through the crimp cycle. If you press it part way it will not release the crimped end. These are very repeatable but still need to be checked periodically.

Most wire has a printed information on it that has the gauge and insulation type. I have not dissected the old cables to see what the print says. All I really know is that my car was plagued with 1209 codes and going into limp mode until I replaced the cables with the gen 2 set.

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