Key Questions to Ask When Ordering Automotive Hook Up Wire

Understanding Wire Types

Please visit our website for more information on this topic.

There are many types of electrical wire. Understanding which type is best for your application can be confusing. It is important to make the proper selection. Using the wrong type of wire can lead to failures and fires.

For this article, we will focus on the wire typically used in automotive, boat, RV, and motorcycle applications. Never use wire intended for household use in vehicles, it is not designed to handle the heat, vibration, and chemical exposure.

BEWARE of wire sold on discount sites, or any wire sold at too-good-to-be-true prices. Often this cheap wire is actually aluminum with a thin copper coating. Aluminum is only 60% as conductive as copper, so you'd have to use a much larger gauge to carry the same load. We also often see wire labeled as one guage thicker than it actually is, or has stiff/brittle insulation, or is contructed with fewer strands. For the record, Wiring Depot wire is manufactured in the USA and is constructed of 100% copper. We guarantee it to be true to spec/gauge and adhere to industry SAE standards - for instance our primary wire is ROHS compliant and made to SAE J specifications.

1.&#;GPT&#; or &#;Primary&#; Wire

This is the most common wire you find at auto stores. As its name implies, it is a good general purpose automotive wire. It features a multi stranded core and flexible insulation making it ideal for pulling through tight spaces. It is usually rated to 80ºC (176ºF). Although some is also rated to 105ºC (221ºF). It is resistant to oil, chemicals and acids.

See our selection of Primary Wire HERE

2.&#;&#; &#;Hook-Up&#; or &#;Motor&#; Wire

The biggest difference between GPT and Motor wire is that motor wire features finer strands of wire. This allows it to handle higher voltages.

Motor wire is rated at 600 Volts with a temperature rating of 105ºC (221ºF). It is resistant to grease, oil, acids, water, solvents, fungus.

Although most commonly used as internal wiring in appliances and HVAC equipment, motor wire is finding increasing use in automotive applications.

See our selection of Motor Wire HERE

3. SXL Wire

SXL Wire features a cross linked polyethylene jacket that can withstand higher heat, abrasion, and aging better than GPT wire. It is often the preferred choice in higher stress applications like race or industrial use vehicles. If you are looking for extra durability, this is a good choice.

GXL and TXL wire feature the same type of insulation but thinner walls to make it easier to pull through tight spaces.

See our selection of SXL Wire HERE

4.Speaker Wire

Speaker wire is a paired stranded wire intended for audio applications. As the name implies it is meant to carry the 'sound' from a stereo receiver to the speakers. It is intended for low voltage use and should never be used to carry load. Speakers can run in 'reverse' (out of phase) but they will sound terrible - so it is important that the + and - terminals be connected correctly.

See our selection of Speaker Wire HERE

If you are looking for more details, kindly visit Suntex Electronics.

5. Battery Cable

Battery cable is typically used to connect the battery to the car&#;s electrical system (typically at the starter) and ground. It is larger gauge, heavier wire. Battery cables are most susceptible to corrosion, and can often be corroded inside the cable where it can&#;t be seen. If you are having starting issues, check your battery cables carefully.

See our selection of Battery Cable HERE

6. Trailer Wire

Trailer wire is typically GPT or Primary wire that is colored and configured for common trailer applications. Most trailers use a common coloring system that uses Green, Yellow, Brown, and White for the various lighting functions. Purchasing 'Trailer' Wire makes a trailer re-wiring or repair project simpler. It also helps in future diagnosis of problems.

See our selection of Trailer Wire HERE

If you've ever had questions about the types of wires used in vehicles, automotive industry standards, common insulation materials, gauge determination, or customization options, you're in the right place. In this blog, we'll provide clear and concise answers to frequently asked questions about automotive wires to help you make informed choices to navigate the world of automotive wiring.

What types of wire are commonly used in the automotive industry?

Automotive primary wire and battery cable are the two most common types of wire and cable that are used in the Automotive industry. Other than primary wire and battery cable, Allied Wire and Cable also carries various other types of common automotive wire, such as brake cable, car speaker wire, fusible links, and trailer cable.

What standards should be considered when choosing automotive cable?

Common standards for the automotive industry include those created by the Society of Automotive Engineers (SAE), the American Society for Testing and Materials (ASTM), Underwriters Laboratories (UL), and the Recreational Vehicle Industry Association (RVIA). It is also important to consider the specifications set by individual car manufacturers. Allied Wire and Cable&#;s automotive primary wire meets all Ford and Chrysler standards.

What insulation is commonly used in primary wire?

The most commonly used insulation materials for automotive applications Polyvinyl Chloride (PVC) and Cross-Linked Polyethylene (XLPE). PVC insulation is often heated and then extruded through a dye on the stranding. PVC can be melted with a heat source to change its form. Cross-linked insulation is created by extruding the material through a tube under heat and pressure to change the molecules of the insulation to another state. The main difference between the two are the temperature ranges. A cross-linked automotive wire can withstand much higher temperatures. Regardless of insulation material, both wires share a voltage rating of 50V. There are three main wires for both insulations, all of which are primary/general use wires.

• PVC automotive wire:
  • GPT - used for general circuit wiring and rated to 80 °C
  • TWP - lead-free, thin wall automotive wire rated to 105 °C
  • HDT - heavy wall automotive wiring rated to 80 °C
• Cross-linked automotive wire:
  • GXL&#; thin wall, most common type, works with most standard automotive connectors, rated to 125 °C
  • SXL&#; standard wall, rated to 125 °C
  • TXL&#; extra thin wall, best for applications that require minimal size and weight, rated to 125 °C

Shop Primary Wire

What are the different types of battery cable?

Battery cable is also available in PVC and cross-linked forms. SGT cable is a PVC cable rated at 80° Celsius. It can be used in starters or battery grounds. Cross-linked battery cables can also be used in starter and battery ground applications, and are more resistant to heat, abrasion, and aging than PVC cable. We carry STX and SGX cables. They are both rated at 125° Celsius, but STX has a thinner wall. This makes it popular for automotive applications with limited space. Our Battery Cables also have a voltage rating of 50V.

Shop Battery Cable

How do you determine the gauge (AWG) of automotive wire?

First, make a small cut about 1/2" long and remove the insulation on the automotive wire. Then, count the individual strands of copper and use a micrometer to measure one of the strands. From there, refer to the table below to determine the wire's gauge.

# of strands/strand gauge = wire gauge
7/28 = 20 AWG
16/30 = 18 AWG
19/29 = 16 AWG
19/27 = 14 AWG
19/25 = 12 AWG
19/23 = 10 AWG
19/21 = 8 AWG
37/21 = 6 AWG

How can I customize my automotive wire?

We offer several customization services for our automotive wires. Both PVC and cross-linked automotive wire can be printed with custom text or company logos and striped with up to three tracers. PVC automotive wire can also be dyed for easy identification.

Automotive Wire Catalog

Contact us to discuss your requirements of Automotive Hook Up Wire. Our experienced sales team can help you identify the options that best suit your needs.