This invention relates to an aluminum conductor composite core reinforced cable and method of manufacture. The composite core comprises a plurality of longitudinally extending fibers embedded in a resin matrix. The composite core comprises the following characteristics: tensile strength ranging from about 250 to about 350 Ksi; a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to about 6×10−6 cm/cm·° C. The composite core is further manufactured according to a two die pultrusion system, the system comprising tooling designed in accordance with the processing speed, selection of composite core fibers and resin and desired physical characteristics of the end composite core.