GRUNT 87 Posted August 22, 2013 I like the plug idea. Do they make a plug that can be placed into the sheet metal? Share this post Link to post Share on other sites
PMA4x4 4 Posted August 22, 2013 Are talking about where it would be flush mounted? I looked that up and could not find anything. They have one that says "panel mounted" but its not flush. Share this post Link to post Share on other sites
PMA4x4 4 Posted August 25, 2013 Wired up the battery side of the quick disconnect for the winch Making Weatherpack connectors for the Tranny temp sending unit and the dual fan controller. Finally got to making custom cables for the dual battery setup. Mid project, what a mess. Initial testing of the wiring with the smart solenoid. Share this post Link to post Share on other sites
scottL 169 Posted August 25, 2013 Mid project, what a mess. That looks vaguely familiar.. Ain't electrical fun? Projects' shaping up nicely. Share this post Link to post Share on other sites
PMA4x4 4 Posted August 26, 2013 Everything before was test fit, then it all had to come back out for final welding, assembly and the bracket needed to be painted. Wiring officially begins. The custom bracket assembly to hold 2 batteries, 2 relay boxes, 1 washer fluid jar, 1 battery charger and 1 ARB air compressor painted in satin epoxy. Batteries, solenoid fan controller and 1st relay box official bolted in. Share this post Link to post Share on other sites
PMA4x4 4 Posted August 26, 2013 the washer fluid jug was on the fender and the charcoal canister well... I seriously think they thought of the dual battery thing in mind for like the diesels because the bracket that mounts the canister to the fender had mounting holes to drop it 2" which is what i needed to clear the hood. All I did was move the washer jug straight out onto the new frame i built. The Battery mount is from Artec Industries. They do make a single mount for the PC1500 or Diehard equivalent. If you do choose a dual keep in mind the 34/78 (with side posts) will NOT fit with side posts facing in. I still have to get terminal covers. I would have used tinned terminals but I needed to order a larger quantity then I wanted to get at the time. The heat shrink wrapping on all the main cables are weather sealed with a epoxy glue that oozes out and cures when it cools and seals the end. The crimping tool I use it this crimper here. It may seem a bit expensive for such a small task but it gets the job done right. I changed the long bolts on the mill spec terminals from 2.25" to 2.5" so I can double nut as you see. The battery mount came with Allen bolts and nuts but that would have been almost impossible to get to the nuts underneath so I made my own nut strips with extra length on an end for a handle. All the main cable is 2ga with the extra abrasive resistant cover. I test this stuff and you practically have to saw into it to get thru. Its stiff as hell but it isnt gonna wear thru and ground out. The grey wires off the positive terminal or fusible links for the two relay/fuse boxes. The relay boxes used 10ga wire both fro the positive and negative. All heat shrink is the weather seal stuff. Share this post Link to post Share on other sites
theksmith 3,589 Posted August 26, 2013 looks good! wiring is one of those things that takes time to get it right, but it's also something that really needs to be done right Share this post Link to post Share on other sites
PMA4x4 4 Posted August 26, 2013 Totally true. This is why it has taken so long to get this part of the electrical project finished. waiting on the right parts which requires $$$ then the right time to do it all in one shot. Share this post Link to post Share on other sites
PMA4x4 4 Posted August 27, 2013 Getting around to making my own 1" Zero rate springs. Share this post Link to post Share on other sites
