Which size wire is best for making a harness

Can I use the same size wire to make a Y series harness, loop key and run to the charge port? or what is recommended. I will be using xt90s

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Sure. But might as well make the charge wire a smaller gauge as it is sending less amperage. Fuse it though.

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Is it safer to go bigger like 10 awg, and what’s the recommended awg size for the charging wires?

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You can go to big sometimes. 12 is pretty much the standard unless you are etoxx and that dude is just off the hook. :metal::rofl:

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If in doubt, use 12AWG power wires and 20AWG charge wires with a 10A fuse on the charge port.

Only use high-strand-count silicone-insulated wire, sometimes called “Superworm”.

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No, don’t use 10AWG

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Depends Aluminum has half the ampacity of Copper conductors. If you’re not certain you’re ordering 12 awg with copper conductors - get 10 awg.

12 awg multi-stranded silicone wire made with copper is perfectly sufficient. 12 awg aluminum will get HOT