I was all set to do the "eliminate the connector" drill and direct-connect the stator wires to the r/r wires, but now see that apparently a "standard" connection won't work for long. You used "10G spade lugs" and I found this site/pic that shows those: http://workmanship.nasa.gov/lib/insp/2%20books/links/sections/206%20Spade%20Lug%20Terminals.html
1. How did you use spade lug connectors to make the connection? It looks like these go under a bolt head, or something like that, not attached to one another. Did you have one of these lugs on each side?
2. You used 10G lugs - what is the gauge of the stator and r/r wires? It looks smaller than 10 gauge to me, so wouldn't the lug not fit very well? Or am I misunderstanding?
I just want to do this job right, the first time. Thanks for any help.
Well I guess the ones I used aren't true "spade" lugs since they have a hole not a slot. I simply bolted them together, and covered 'em with shrink tube. The stator/R/R wires are 12G, but you can put 10G connectors on 'em just fine. Just gotta crimp 'em a bit more. I ALWAYS solder too. Don't trust crimping alone to provide a good electrical connection.
The ones I used look like the yellow one on the R: