Apex High Output Alternator

High-Output Alternators: Important Installation Guidelines

Before installing your new high-amperage alternator, please review these essential requirements to ensure maximum performance and avoid voltage drops:

• Battery & Wiring: Running a high-output alternator with a stock battery can cause voltage drops. You must ensure you have a strong battery, proper wiring, and a solid ground connection.

• The "Big 3" Upgrade: Although not strictly required, we highly recommend upgrading the three main electrical cables in your vehicle before installation:

  • The Power Cable: Connects the alternator to the battery.

  • The Ground Cable: Connects the battery to the chassis.

  • The Engine Block Ground: Connects the engine block to the chassis. (Upgrading these cables ensures a consistent power source, reduces system strain, and extends the lifespan of both your battery and alternator).

• Belt Size: Each high-output alternator comes equipped with an overdrive pulley, which is smaller than the factory pulley. Because of this, you will need a slightly smaller belt to prevent slipping.

  • Tip: Find your factory belt part number; generally, the next size down will fit perfectly.

  • Need help? Download the Belt Dimension & ID Guide (PDF). If you can't find your size, let us know and we will find the correct part number for you! 

Premium Hairpin Technology

We specialize in bringing advanced 6-Phase Hairpin Technology to your vehicle, replacing older, less efficient factory slot-wound alternators to deliver ultimate reliability and power output ranging from 220A to 500A.

Key Technical Benefits

• Heavy-Duty Diodes: Small-case alternators feature 60 Amp diodes (instead of the standard 25 Amp), while large-case models utilize up to 100 Amp diodes.

• Superior Rectifiers: Features a 12-diode setup with a dual bridge rectifier for maximum efficiency. Large-case models include a finned rectifier for heavy-duty cooling and durability.

• Premium Stators: Our 6-Phase hairpin stators feature square wire laid flat in a lamination stack, hand-soldered and welded in-house using robust OEM components.

Custom Machining & Perfect Fitment

Every alternator we quote is designed as a direct bolt-on replacement:

• OEM Fitment: We spend thousands of hours custom CNC-cutting brackets and milling out factory housings so that the unit bolts up exactly like your stock alternator.

• Direct Plug / Harness Options: Includes custom 3D-printed plugs for a seamless connection to your factory wiring harness whenever applicable. (Note: Certain high-amperage custom applications require bypassing the factory plug to set voltage directly at 14.8V).

Advanced Voltage Control Options

1. Computer Bypass & Extension Harnesses

Many modern vehicles use the factory computer to regulate voltage, which can shut off the alternator until accessories like the A/C or headlights are turned on. Our custom extension harnesses bypass this restriction to deliver a stable, healthy 14.8V set-point. (Note: While this safely optimizes your electrical system without cutting wires, it may occasionally trigger a factory battery light on certain vehicles).

2. Lithium Booster Harnesses (For LTO / Lithium Cells)

For specialized high-performance setups running lithium batteries, we offer booster harnesses to adjust voltage set-points:

• Available Set-Points: 15.3V–15.5V | 15.5V Solid | 15.6V–15.8V.

• Requirements: Only available for Hairpin Style alternators with a GM-style plug ("P L F S" Pin Code).

• Pricing: Starts at $45.99 shipped (Contact us for exact vehicle availability).