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Old 01-04-2024, 01:24 PM #1
Daryl Elmore Daryl Elmore is offline
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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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Old 01-04-2024, 01:49 PM #2
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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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Old 01-04-2024, 06:27 PM #3
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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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Old 01-04-2024, 06:58 PM #4
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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
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Old 01-05-2024, 01:05 PM #5
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Quote:
Originally Posted by phattyduck View Post
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
any mods needed to put in the suzuiki grand vitara denso in ?
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Old 01-05-2024, 01:41 PM #6
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Quote:
Originally Posted by 3bears View Post
any mods needed to put in the suzuiki grand vitara denso in ?
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
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Old 01-05-2024, 05:42 PM #7
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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 View Post
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
Is a very slick way of mounting it as well.
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Old 01-06-2024, 02:37 PM #8
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Quote:
Originally Posted by phattyduck View Post
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

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
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Last edited by 3bears; 01-06-2024 at 02:52 PM.
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Old 01-08-2024, 12:56 PM #9
Daryl Elmore Daryl Elmore is offline
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Quote:
Originally Posted by phattyduck View Post
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
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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Old 01-08-2024, 04:30 PM #10
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Quote:
Originally Posted by Daryl Elmore View Post
Thats an awesome idea. How thick and wide is the brass bar you used?
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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Old 01-09-2024, 12:41 PM #11
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Quote:
Originally Posted by phattyduck View Post
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
Awesome! Thank you sir, I have my next project.
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Old 01-10-2024, 02:57 AM #12
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Quote:
Originally Posted by phattyduck View Post
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
This is absolutely amazing. You've given me quite a few ideas with this kind of setup. Thanks!
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