?? Thats not how wiring works. The alternator doesnt supply more current to undersized wiring making it dangerous (If it did a larger higher cca battery would be just as dangerous no?) If the wiring is undersized and not protected its just as dangerous regardless. For one thing even a stock 60 amp alternator can typically be only producing like 20 amps in a c3 during the day with the ac and radio off and the battery topped off but if some "dangerous undersized circuit was trying to pull say 40 amps all by itself? well than the 60 amp alternator would heat up, drag the engine down with its max load and output its full capacity ouputting the extra 40 amps to the circuit and be at 60 amps output. If the alternator cant meet this demand than the battery will until its drained. These fans draw 14-15 amps each. I have them as well and have tested them. They draw more on startup for a very short time but the battery has enough reserve to supply that.

He could run a 500amp alternator and it wont effect the safety of his wiring one bit. Just as going to a larger electrical service like 100 amp to 200amp from a pole to a house wont make the existing house wiring any more dangerous in any way. If it did you would be seeing fires from people plugging in an led light with wimpy wiring that draws 2 amps into outlets that supply up to 20 amps with a 20 amp breaker.

Those stock circuits are not effected and still only draw what they are sized to with the appropriate fuses or breakers. An alternator only produces the amount amps the electrical system load is trying to pull.. If anything an undersized alternator is more of a heat / fire risk hazard. If the rest of the wiring in the car was improperly wired for some reason without proper fuses or breakers and something was trying to draw more than it would still be a fire hazard drawing from a battery which typically can supply over 500amps.

Its already been mentioned he should move power feed for the fans to the starter AFTER beefing up the power wire from the alternator to the starter and swapping that fan breaker to fuses. This is a simple and inexpensive task. Far less expensive and less work than purchasing the hardware and reverting to the clutch fan which less face it, was already swapped out for a reason whether it was a good one or even an issue the fans can correct.


OP as far as the extra load being drawn by the electric choke heater coil which is being drawn the entire time the engine is running..someone mentioned those are typically on their own fused line.. That said a typical Holley electric choke draws about 6-7 amps when cold and slowly tapers down to less than an amp of draw so...

 

Augie, you are correct, assuming those wires have circuit protection close to the source. If you have no circuit protection, and you exceed the ampacity of the wire gauge, it will 100% fry that wire (how quickly depends on how much you are exceeding the ampacity, i.e.,how quickly it heats up.