Dual Battery System

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

The Dual Battery System is in and its taken a fair bit of planning and space allocation but I have installed the heavy wiring, breakers, trip switches and rear accessory sockets to my Prado.

Due to the limited space we made drill templates and performed dummy installations before finally drilling the car and fitting wiring and parts.

I am now jigging up for final tooling and I am very happy with the progress we have made. The battery tray worked out great with a perfect a/c and power-steering mod that won't affect any factory warranties. Petrol and diesel models will use the same tray.

Notes: Due to the a/c pipework the battery space is limited to 10 inches or 255mm. Even after moving and relocating the a/c mounting bracket we can only fit a 60ah battery. With this limited space we have made the new battery a high cca battery for starting the engine and made the old starting battery the new aux battery. (N70 / 12 inch fits here).

Regards

Derek from ABR






The image below shows the a/c mounting on the petrol and diesel, this common mounting point limits battery size. The pipe is a rigid pipe and has 'T' offs for the rear a/c so can't be moved.



Note: The Black bracket can not be removed only bent 90 deg out of the way as the common bolt holds the bracket to the a/c pipe and also compresses the a/c o-ring. (Do not attempt to loosen this bracket as you will loose the a/c gas.)

[BenTas Member Find all posts View Profile Close BenTas]

Re: Dual Battery System

Nice.................Very nice. Top Job, wanna come to Tas and do mine

[stephenvsl Member Find all posts View Profile Close stephenvsl]

Re: Dual Battery System

Thanks for showing us your set up Derek - it's always great to have pioneers for these sort of things. I notice the circuit breakers you have for the rear bar and cargo area are similar to ones I got through eBay to use for my dual battery install (I guess the different colours are different ratings). Mine are 200amp and I use them instead of mega fuses, I have another type of circuit breaker for the accesories. Did you fuse the batteries or use circuit breakers? Are you selling these circuit breakers now through your site or did you get yours somewhere else?

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Thanks for showing us your set up Derek - it's always great to have pioneers for these sort of things. I notice the circuit breakers you have for the rear bar and cargo area are similar to ones I got through eBay to use for my dual battery install (I guess the different colours are different ratings). Mine are 200amp and I use them instead of mega fuses, I have another type of circuit breaker for the accesories. Did you fuse the batteries or use circuit breakers? Are you selling these circuit breakers now through your site or did you get yours somewhere else?

Hi Stephen, everything used for the install is my own product. Yes the colours are ratings on the trip switches and I have used auto reset breakers for the other circuits, I then fused the individual accessories as required. The main battery cable is not fused as it is now the new cranking supply cable. The DBi120 is not fused as the cables are less than 60cm long and well insulated. Once the new monitors arrive these cables will also be capable if emergency linking of the batteries with the 'R' function now added to the DBi120. Space is very limited on the Prado 150 so plan your layout well before drilling any holes, I will try make drill templates available soon. The bonnet gas struts also use up valuable space so mark this area 'out of bounds'.

Note: The monitor can be used with most isolators that have an override function.

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Here is the space that should be kept free for the gas strut.

[stephenvsl Member Find all posts View Profile Close stephenvsl]

Re: Dual Battery System

Hi Derek,

The installation of the Anderson plug in the rear is particulary neat. Did you just drill through the bottom of a standard plug or is there a special plug with entry from the bottom? Would seem a bit tricky for me to fit the wires through, terminate them and push them home if the entry was from the bottom. If you drilled, did you terminate first and then fit the wires and lugs through? I bought all the cabling through you for my dual battery and want to thank you for your speedy service (as a customer I also claim 1/1,000,000 ownership of your 150 through my purchases!! )

Stephen

[clifton Advanced Member Find all posts View Profile Close clifton]

Re: Dual Battery System

Hi Derek,

The installation of the Anderson plug in the rear is particulary neat. Did you just drill through the bottom of a standard plug or is there a special plug with entry from the bottom? Would seem a bit tricky for me to fit the wires through, terminate them and push them home if the entry was from the bottom. If you drilled, did you terminate first and then fit the wires and lugs through? I bought all the cabling through you for my dual battery and want to thank you for your speedy service (as a customer I also claim 1/1,000,000 ownership of your 150 through my purchases!! )

Stephen

Strewth I reckon I own 3/1,000,000 of Dereks 150 and now my mate wants me to mod his new 200 series like my 120, more copper and bits a pieces required when will it ever end :lol:

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Hi Derek,

The installation of the Anderson plug in the rear is particulary neat. Did you just drill through the bottom of a standard plug or is there a special plug with entry from the bottom? Would seem a bit tricky for me to fit the wires through, terminate them and push them home if the entry was from the bottom. If you drilled, did you terminate first and then fit the wires and lugs through? I bought all the cabling through you for my dual battery and want to thank you for your speedy service (as a customer I also claim 1/1,000,000 ownership of your 150 through my purchases!! )

Stephen

Hi Stephen

I used my drill templates that I have made and then drilled and slotted the rear section of the Anderson plug. This is then filled with silicone to stop dust and dirt entering the plug. Yes I agree a neat fit and quite serviceable too.

Regards

Derek

[bilo33prado Senior Member Find all posts View Profile Close bilo33prado]

Re: Dual Battery System

Love your work ABR-SIDEWINDER. Checked out your web page and it looks the goods How much for the DIY dual battery system from you guys, wiring harness, battery, solenoid and all the bits to set up 2nd battery to run Fridge in the (little) boot of a NG Prado 150?

P.s have you looked at 240v inverter upgrades for NG Prado as well? Say 500 - 1000w?

[ozwapet2 Advanced Member Find all posts View Profile Close ozwapet2]

Re: Dual Battery System

Looks great design, the only comment I would make is the the meter face of the analogue voltmeter may be prone to damage.

[bevwone Member Find all posts View Profile Close bevwone]

Re: Dual Battery System

Great setup Derek.

I do not want to highjack the thread but I have a couple of questions.

I have your dual battery system for the 120 with a redarc and override button that joins the batteries. I am very interested in the new monitor. Does this replace the tester that came with your system?

You mentioned that it can be used with most isolaters that have an override function. Does this include Redarcs? Also - When are they available and are prices available yet?

Note: The monitor can be used with most isolators that have an override function.

I am also looking to doing something similar to the cargo bay. What rating is the circuit breaker (orange) to the cargo bay? And, what gauge wire are you running to the fuse block?

I am thinking of running a 40l engel (you made a the engel plug and wiring to the rear when I purchased the dual battery system), 2 X 20A hella plugs and a LED lighting strip from the fuse block?

Thanks in advance.

Bevan.

PS Welcome aboard - I am very impressed with your system and your assistance when I installed it.

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Love your work ABR-SIDEWINDER. Checked out your web page and it looks the goods How much for the DIY dual battery system from you guys, wiring harness, battery, solenoid and all the bits to set up 2nd battery to run Fridge in the (little) boot of a NG Prado 150?

P.s have you looked at 240v inverter upgrades for NG Prado as well? Say 500 - 1000w?

Pricing still needs finalising but should be around $300 for the base kit, $125 for the Power outlet kit and $95 for the trailer charge cable. (Battery not included)

The inverter can't be changed due to the limited space available as the rear a/c takes up most of it. Inverters will need to be fitted to cargo barrier or drawer system.

Regards Derek

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Great setup Derek.

I do not want to highjack the thread but I have a couple of questions.

I have your dual battery system for the 120 with a redarc and override button that joins the batteries. I am very interested in the new monitor. Does this replace the tester that came with your system?

You mentioned that it can be used with most isolaters that have an override function. Does this include Redarcs? Also - When are they available and are prices available yet?

Note: The monitor can be used with most isolators that have an override function.
I am also looking to doing something similar to the cargo bay. What rating is the circuit breaker (orange) to the cargo bay? And, what gauge wire are you running to the fuse block?

[quote:24tubudb]

I am thinking of running a 40l engel (you made a the engel plug and wiring to the rear when I purchased the dual battery system), 2 X 20A hella plugs and a LED lighting strip from the fuse block?

Thanks in advance.

Bevan.

PS Welcome aboard - I am very impressed with your system and your assistance when I installed it.

[/quote:24tubudb]

Yes the new monitor will be our new standard monitor and replace the battery tester.

Yes the override can be used with the Redarc SBi12.

I used the 40A trip switch and 10mm2 cable.

Thank You for the welcome note.

Regards Derek

[bilo33prado Senior Member Find all posts View Profile Close bilo33prado]

Re: Dual Battery System

Should run fridge ok but better of running outlet off 2nd battery with thicker cable and installing some 12v outlets down the back to run other gear off at same time and with the ignition off, But if you just need to run fridge whilst driving then should be cool 8)



Think ABR-SIDEWINDER said not enough room to replace with bigger inverter as rear aircon takes up all the space?

Love your work ABR-SIDEWINDER. Checked out your web page and it looks the goods How much for the DIY dual battery system from you guys, wiring harness, battery, solenoid and all the bits to set up 2nd battery to run Fridge in the (little) boot of a NG Prado 150?

P.s have you looked at 240v inverter upgrades for NG Prado as well? Say 500 - 1000w?

Pricing still needs finalising but should be around $300 for the base kit, $125 for the Power outlet kit and $95 for the trailer charge cable. (Battery not included)

The inverter can't be changed due to the limited space available as the rear a/c takes up most of it. Inverters will need to be fitted to cargo barrier or drawer system.

Regards Derek

[ABR-SIDEWINDER Member Find all posts View Profile Close ABR-SIDEWINDER]

Re: Dual Battery System

Tooling is complete and the final result is better than expected.

I have also decided to supply cell saver heat sleeves with the trays as we sourced a batch at very reasonable prices.

Here are some photo's of the final project.









Final and maximum battery size is 250mm restricted by the a/c pipe. The picture shows a 225mm MRV48.

I will take some photo's of the 'orbital' and also the 'optima' for the site later.

Regards

Derek.