01-04-2024, 01:24 PM
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#1
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Junior Member
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Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
Posts: 10
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Junior Member
Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
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Positive battery terminal organization
Hey all, I just upgraded to the Caddi alternator and did the big 3 upgrade while I was at it after having a lack of power issue while trying to winch out of a predicament. The problem is now I have so much attached to the positive terminal its just a mess. What's connected is: Main power form the harness, power to the fuse box, and the wire to my Auxbeam control box. Those are the smaller wires. The big wires are the 00 gauge Winch power, 4 gauge Amp power and now the 1/0 power from the alternator. What have any of you done to clean up this much on the battery?
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01-04-2024, 01:49 PM
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#2
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Senior Member
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Join Date: Jul 2011
Location: St. Louis
Posts: 1,082
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Senior Member
Join Date: Jul 2011
Location: St. Louis
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I am using these: https://www.amazon.com/Fastronix-Mil...A2GNZBM8JSG24J
Well, dual battery setup, they're on the yellowtop house battery that gets the heavy winching loads.
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'99 Highlander 5-spd manual e-locker no-running-board
SS 3" suspension lift/1" body lift/33" tires/'Snowflake' TRD Taco wheels/231mm Tundra brakes/bumpers/armor/sliders/winch/Sherpa Matterhorn rack
Manual front hubs, NWF Eco-crawler transfer case doubler, second gas tank
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01-04-2024, 06:27 PM
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#3
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Join Date: Jun 2020
Location: UT
Age: 20
Posts: 488
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Join Date: Jun 2020
Location: UT
Age: 20
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https://www.oreillyauto.com/detail/c...01/08506?pos=3
I just bought these from O'Reilly's, put all the OEM stuff on one side of each terminal and anything aftermarket on the other.
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1998 4Runner Limited 4WD w/Rear Locker
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01-04-2024, 06:58 PM
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#4
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Elite Member
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Join Date: Mar 2016
Location: Pasadena, CA
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Join Date: Mar 2016
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I got new OEM replacement terminals meant for an Avalon from around the same vintage:
90982-06022
90982-05035
Then, I made a custom buss bar to run off the positive terminal (copper bar, bend and drilled):
It has:
Headlight harness
Offroad light harness
Trailer brake and charge (on breakers)
Winch (also on breakers, but can easily be bypassed if needed)
It is wrapped with both heat shrink and silicone fusing tape for protection.
The ground side just has the engine, fender and winch connections. Charge wire, ground wires, etc are routed as OEM but all 4 gauge. Alternator is a 105 amp Denso from a Grand Vitara.
-Charlie
__________________
'99 4Runner SR5 Auto - 4WD swapped
'89 Camry Alltrac LE 3S-GTE 5spd
'17 Chevy Volt Premier
'16 Honda Odyssey Elite
Previous: '88 Camry Alltrac LE 3S-GE BEAMS, 90 Camry 3S-GTE, 90 Camry DX, '03 WRX wagon, '08 Outback XT
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01-05-2024, 01:05 PM
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#5
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Senior Member
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Join Date: May 2015
Location: north east of Fairbank out there in the frontiers Alaska
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Real Name: 3 Bears
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Senior Member
Join Date: May 2015
Location: north east of Fairbank out there in the frontiers Alaska
Posts: 3,179
Real Name: 3 Bears
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Quote:
Originally Posted by phattyduck
I got new OEM replacement terminals meant for an Avalon from around the same vintage:
90982-06022
90982-05035
Then, I made a custom buss bar to run off the positive terminal (copper bar, bend and drilled):
It has:
Headlight harness
Offroad light harness
Trailer brake and charge (on breakers)
Winch (also on breakers, but can easily be bypassed if needed)
It is wrapped with both heat shrink and silicone fusing tape for protection.
The ground side just has the engine, fender and winch connections. Charge wire, ground wires, etc are routed as OEM but all 4 gauge. Alternator is a 105 amp Denso from a Grand Vitara.
-Charlie
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any mods needed to put in the suzuiki grand vitara denso in ?
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2000 SR-5 Highlander version 4:30's, factory locker , green, bought 6/21
2001 SR-5... bought 11/20..sold 6/21....
2000 SR-5 moded, lifted, e locker, other cool stuff, totaled 10/20
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01-05-2024, 01:41 PM
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#6
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Elite Member
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Join Date: Mar 2016
Location: Pasadena, CA
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Quote:
Originally Posted by 3bears
any mods needed to put in the suzuiki grand vitara denso in ?
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1st gen 105 amp bolt in alternator. | Tacoma World
Drill out one mounting ear. The connectors are in a slightly different location, but fit and plug in just fine.
-Charlie
__________________
'99 4Runner SR5 Auto - 4WD swapped
'89 Camry Alltrac LE 3S-GTE 5spd
'17 Chevy Volt Premier
'16 Honda Odyssey Elite
Previous: '88 Camry Alltrac LE 3S-GE BEAMS, 90 Camry 3S-GTE, 90 Camry DX, '03 WRX wagon, '08 Outback XT
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01-05-2024, 05:42 PM
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#7
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Senior Member
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Join Date: Apr 2020
Location: Monroe, WA
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Real Name: Devan
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Senior Member
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Location: Monroe, WA
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Bus bars sound like what you want. if those aren't enough, a 34/78 group battery should help (double terminal). I have some epoxied to the top of my 34/78 battery to make things cleaner. However, this -
Quote:
Originally Posted by phattyduck
I got new OEM replacement terminals meant for an Avalon from around the same vintage:
90982-06022
90982-05035
Then, I made a custom buss bar to run off the positive terminal (copper bar, bend and drilled):
It has:
Headlight harness
Offroad light harness
Trailer brake and charge (on breakers)
Winch (also on breakers, but can easily be bypassed if needed)
It is wrapped with both heat shrink and silicone fusing tape for protection.
The ground side just has the engine, fender and winch connections. Charge wire, ground wires, etc are routed as OEM but all 4 gauge. Alternator is a 105 amp Denso from a Grand Vitara.
-Charlie
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Is a very slick way of mounting it as well.
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Y2K Highlander Millennium Silver 3.4L auto @ 320k and climbing
Toytecs + 5100s / 7.5 wrap + OME spacers + Tokicos / JBA UCAs / Anonymous Fab. LBJs / Total Chaos Gussets / EimKeith PCK + LCAR / Extended Bump Stops; Brake Lines; Rear Diff Breather / True North Fab. Hybrid Bumper / CBI Hybrid Bumper + Tire Carrier / 4xInnovations Hybrid Sliders / Opt Offroad Trailing Arms / Lil Skip Gas Skid / BudBuilt Front Skid / ARB Rear Locker
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01-06-2024, 02:37 PM
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#8
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Senior Member
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Join Date: May 2015
Location: north east of Fairbank out there in the frontiers Alaska
Posts: 3,179
Real Name: 3 Bears
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Senior Member
Join Date: May 2015
Location: north east of Fairbank out there in the frontiers Alaska
Posts: 3,179
Real Name: 3 Bears
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Quote:
Originally Posted by phattyduck
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very nice, thanks for the link, just read most of it...even though the denso in my rig is only 1 year old, im gonna do this upgrade before next winter, that and bigger wire from alternator and a new battery
in my first rig ( totaled) I did the caddy alt upgrade and did not like it, the shimming and having to change out the wires for the alternator....I like that this is basically plug and play....except drill out a hole
and the denso rebuilt (2100461) 105 amp is cheaper than the stock denso rebuilt 80 amp at rock auto,
side note, just put in a denso rebuilt starter, and the old one was killing my amps...now im back to stock amp output...but here in winter I want more esp at idle
thanks again for the link
__________________
2000 SR-5 Highlander version 4:30's, factory locker , green, bought 6/21
2001 SR-5... bought 11/20..sold 6/21....
2000 SR-5 moded, lifted, e locker, other cool stuff, totaled 10/20
Last edited by 3bears; 01-06-2024 at 02:52 PM.
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01-08-2024, 12:56 PM
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#9
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Junior Member
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Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
Posts: 10
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Junior Member
Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
Posts: 10
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Quote:
Originally Posted by phattyduck
I got new OEM replacement terminals meant for an Avalon from around the same vintage:
90982-06022
90982-05035
Then, I made a custom buss bar to run off the positive terminal (copper bar, bend and drilled):
It has:
Headlight harness
Offroad light harness
Trailer brake and charge (on breakers)
Winch (also on breakers, but can easily be bypassed if needed)
It is wrapped with both heat shrink and silicone fusing tape for protection.
The ground side just has the engine, fender and winch connections. Charge wire, ground wires, etc are routed as OEM but all 4 gauge. Alternator is a 105 amp Denso from a Grand Vitara.
-Charlie
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Thats an awesome idea. How thick and wide is the brass bar you used?
Last edited by Daryl Elmore; 01-08-2024 at 01:38 PM.
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01-08-2024, 04:30 PM
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#10
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Elite Member
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Join Date: Mar 2016
Location: Pasadena, CA
Posts: 5,441
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Elite Member
Join Date: Mar 2016
Location: Pasadena, CA
Posts: 5,441
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Quote:
Originally Posted by Daryl Elmore
Thats an awesome idea. How thick and wide is the brass bar you used?
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Copper (don't think brass would like to bend), 1/8" thick, 3/4" wide. I used 12" stick of it, bought through McMaster.
-Charlie
__________________
'99 4Runner SR5 Auto - 4WD swapped
'89 Camry Alltrac LE 3S-GTE 5spd
'17 Chevy Volt Premier
'16 Honda Odyssey Elite
Previous: '88 Camry Alltrac LE 3S-GE BEAMS, 90 Camry 3S-GTE, 90 Camry DX, '03 WRX wagon, '08 Outback XT
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01-09-2024, 12:41 PM
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#11
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Junior Member
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Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
Posts: 10
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Junior Member
Join Date: Jul 2022
Location: Coeur d' Alene, Idaho
Posts: 10
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Quote:
Originally Posted by phattyduck
Copper (don't think brass would like to bend), 1/8" thick, 3/4" wide. I used 12" stick of it, bought through McMaster.
-Charlie
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Awesome! Thank you sir, I have my next project.
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01-10-2024, 02:57 AM
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#12
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Junior Member
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Join Date: Jan 2024
Posts: 8
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Junior Member
Join Date: Jan 2024
Posts: 8
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Quote:
Originally Posted by phattyduck
I got new OEM replacement terminals meant for an Avalon from around the same vintage:
90982-06022
90982-05035
Then, I made a custom buss bar to run off the positive terminal (copper bar, bend and drilled):
It has:
Headlight harness
Offroad light harness
Trailer brake and charge (on breakers)
Winch (also on breakers, but can easily be bypassed if needed)
It is wrapped with both heat shrink and silicone fusing tape for protection.
The ground side just has the engine, fender and winch connections. Charge wire, ground wires, etc are routed as OEM but all 4 gauge. Alternator is a 105 amp Denso from a Grand Vitara.
-Charlie
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This is absolutely amazing. You've given me quite a few ideas with this kind of setup. Thanks!
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