Complete 2nd gen dual batt install

[badtoytrd]

I wanted to do a complete write up of the dual batt install using PC1400s so I deleted my initial post to substitute this one.



Parts needed

Batteries
Odyssey PC1400 Amt needed: 2

Columbia Overland dual battery tray
http://www.columbiaoverland.com/prod...l-battery-tray

Custom made tray for aux fuse block

Hardware for aux fuse block plate
M8-1.25, flat washers, and lockwashers for attaching plate to fender nutsets
1/4 x 20 allthread, nuts, locknut, flat washers, and lock washers to support end of plate

National Luna dual battery kit
http://www.sierraexpeditions.com/ind...t_detail&p=543

Military style battery connectors/terminals
http://www.sierraexpeditions.com/ind...uct_list&c=753

Blue Sea aux fuse block
http://www.sierraexpeditions.com/ind...t_detail&p=550

Blue Sea circuit breaker
http://www.sierraexpeditions.com/ind...t_detail&p=185

Cables
http://www.westmarine.com/webapp/wcs...2#.UBm8zELsIdI

Red 2 AWG battery cable P/N: 233718 Amt needed: 6’
Black 2 AWG battery cable P/N: 233726 Amt needed: 6’
Red 4 AWG battery cable P/N: 179523 Amt needed: 3’
Black 4 AWG battery cable P/N: 214551 Amt needed: 3’

Connectors/Lugs
http://www.westmarine.com/webapp/wcs...8#.UBn6QELsIdJ

2AWG heavy duty butt connector P/N: 104259
2AWG heavy duty lug 3/8” stud P/N: 214163
2AWG heavy duty lug 5/16” stud P/N: 291146
2AWG heavy duty lug 1/4” stud P/N: 104309
4AWG heavy duty lug 3/8” stud P/N: 214254
4AWG heavy duty lug 5/16” stud P/N: 214247
4AWG heavy duty lug 1/4” stud P/N: 385799

Braided Sleeving
http://www.buyheatshrink.com/braided...d-sleeving.htm

Red 3/8” PET braided sleeving P/N: BS0375 Ordered 100’ roll
Black 3/8” PET braided sleeving P/N: BS0375 Ordered 100’ roll

Heat Shrink
http://www.buyheatshrink.com/heatshr...lyolefin.htm#B

.4 Red 3:1 heavy wall adhesive lined heatshrink Amt needed: 4’ piece
.4 Black 3:1 heavy wall adhesive lined heatshrink Amt needed: 4’ piece


Tools Needed

Heat gun

Lug/terminal crimper
http://www.harborfreight.com/hydraul...ool-66150.html

Lighter/torch/hot knife to cut braided sleeving



1. Mounted both batteries and Columbia Overland dual battery tray.
photo4-1.jpg

2. Mounted dual battery solenoid and ran controller cable.
photo1.jpg
Ran controller cable under dash and into center console
photo3-3.jpg

3. Spliced engine harness cable that runs to primary battery using 2AWG butt splice then covered with heat shrink for protection.
photo2-1.jpg
The bludge is where I cut and spliced the engine to pos terminal.
photo2-2.jpg

4. Mounted aux fuse block plate to fender nutserts with M8-1.25 and supported end with 1/4 x 20 all thread through the fender.
photo1-2.jpg
Inside fender well where all thread comes through.
photo2-3.jpg

5. Mounted aux fuse block and circuit breaker
photo3-2.jpg

6. Made connections using crimper and heat shrink then covered with braided sleeving.

7. Finished product
photo1-1.jpg

[Rotorgeek]

Wow nice work that looks relay clean. Thanks for all the links.

[TangoBlue]

Very thorough description! Great write-up and go-by to add to the body of knowledge.

Well done!

[Dipodomys]

Looks good, and very similar to what I came up with. I guess great minds think alike! The Blue Sea items are great quality and are reasonably priced, especially on Ebay and various other websites. I sourced a lot of my heavy gauge wiring, terminal ends, etc. on the internet. Great that you provided part numbers. That will help others do some comparative shopping to find the best deals. West Marine has lots of cool stuff but I found that they don't always have the best prices.

Maybe this weekend I'll take some photos of my setup and post them here. I'm surprised at how similar it looks to yours. Wish I'd taken some during the install to share with others.