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Old 05-04-2017, 10:36 PM
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Real Name: Scott
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Dual Battery Installation and Winch (and associated mods)

There was a lot of time spent considering options regarding how and what to install as a sufficient charging system to be able to handle a winch along with various ancillary lights and an inverter. There are several different systems available and different ways to approach it. After considering the options, it was the T-Max dual battery system that ended up having the simplicity and price point that was most appealing.

Before installing all that though, the first thing needed to get the system ready was to do the Big 3 Wire upgrade along with a high output alternator. She got a rebuilt and rewired to 150 amps stock-cased alternator along with a Big 3 Wire Upgrade kit from a user here on T4R.og, so it was out with to old wiring:



This is how things sat until the bumper and winch arrived (sorry, now alternator install pics):



Purchased a RuffStuff Optima Dual Battery Box and started considering what was going to need to move and/or be removed in the general area around the stock battery. The stock radiator overflow bottle needs to be moved and the stock radiator shroud will need to be cut to make room:



All in all, the stock fuse box just needed to have the forward support chopped along with the battery J-bolt hold-down tab:



Had to get a little inventive while figuring out how to hold the tray down so it doesn't slide around everywhere. This is the first iteration:



Ended up making a cross-braced right-angled extension on the inner fender well that was bolted to the relay under the stock battery location and then secured the box with another piece of strapping bolted down from the top:







Next was just wiring up the battery to the charging system along with the controller. Ended up putting the controller in the glove box and also wired a remote connect switch into the dash. The directions were pretty easy to follow and turned out pretty good. The 250 amp solenoid fits nice and snug in the driver's side corner on the firewall (there are 4 relays for various switching functions underneath):



The radiator overflow bottle ended up over between the power steering pump and the airbox. It's a tight fit and there is a need to watch the hose coming out for any signs of breakage:



Installing the winch was pretty straight forward, which of course was complicated by the want of an in cab switch controls instead of just a plug somewhere under the hood. Otherwise, it was a rather normal install. Here's what it looks like under the hood now:



You may notice the two large ANL fuses (80A and 150A) sitting next to the accessory fuse box. One (80A) feeds the four channel amp that powers my speakers in cab, and the other (150A) feeds power to an Energizer EN1100 1100 Watt power inverter that is hidden in the back. It got attached onto the backside of the rear drivers side panel and got a panel for the guts to show the display and control buttons:


Last edited by weekendclimber; 05-09-2017 at 12:23 AM.
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