Okki's Build Thread

[Okki]

Im glad you decided to find a battery that will fit using the factory battery cables. The one thing I've learnt is if something is remotely hard to take off or apart it is USALLY better off being left and not touched.

LOL .... nope.. haven't given up yet on the wire exchange :juggle: Just want to keep things running smooth while I figure it out. Hope to get a bit closer again this weekend as I should have some time to puzzle. Will install the 35D when things go back together. Going to focus on separating the fuse box this weekend since I'm pretty sure I know who/where the cables run to/from the alternator (Yes [MENTION=62008]limamike[/MENTION].. I still need to draw a line diagram. Been out of country, but will do that today or this weekend as well).

 

[Okki]

Battery Groups and Dimensions

The below table contains a comparison table for Battery Group Identification and the associated dimensions. The data was sourced from: http://www.rtpnet.org/teaa/bcigroup.html

The OEM "TrueStart" battery that comes in a 2010+ 4Runner is a Group 24F.

<B><FONT SIZE=+1>BCI GROUP NUMBERS, AND DIMENSIONAL SPECIFICATIONS </FONT></B>

<TABLE BORDER=1 CELLSPACING=0><TR><TH ALIGN=center ROWSPAN=3>BCI
Group
Number </TH><TH ALIGN=CENTER COLSPAN="6">Maximum Overall Dimensions</TH></TR><TR><TD COLSPAN=3 ALIGN=center BGCOLOR="ffff80">Millimeters </TD><TD COLSPAN=3 ALIGN=center BGCOLOR="#80FFFF">Inches</TD></TR><TR><TD ALIGN=CENTER>L </TD><TD ALIGN=CENTER>W </TD><TD ALIGN=CENTER>H </TD><TD ALIGN=CENTER>L </TD><TD ALIGN=CENTER>W </TD><TD ALIGN=CENTER>H </TD></TR><TR BGCOLOR="#C0C0C0"><TD ALIGN=center COLSPAN=7>PASSENGER CAR AND LIGHT COMMERCIAL_BATTERIES 12-VOLT (6 CELLS)</TD></TR><TR><TD align=center>21 </TD><TD align=center bgcolor="#ffff80">208 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">222 </TD><TD align=center bgcolor="#80ffff">8 3/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 3/4 </TD></TR><TR><TD align=center>22F </TD><TD align=center bgcolor="#ffff80">241 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">211 </TD><TD align=center bgcolor="#80ffff">9 1/2 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">8 5/16 </TD></TR><TR><TD align=center>22HF </TD><TD align=center bgcolor="#ffff80">241 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#80ffff">9 1/2 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">9 </TD></TR><TR><TD align=center>22NF </TD><TD align=center bgcolor="#ffff80">240 </TD><TD align=center bgcolor="#ffff80">140 </TD><TD align=center bgcolor="#ffff80">227 </TD><TD align=center bgcolor="#80ffff">9 7/16 </TD><TD align=center bgcolor="#80ffff">5 1/2 </TD><TD align=center bgcolor="#80ffff">8 15/16 </TD></TR><TR><TD align=center>22R </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">211 </TD><TD align=center bgcolor="#80ffff">9 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">8 5/16 </TD></TR><TR><TD align=center>24 </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>24F </TD><TD align=center bgcolor="#ffff80">273 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#80ffff">10 3/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 </TD></TR><TR><TD align=center>24H </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD></TR><TR><TD align=center>24R </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 </TD></TR><TR><TD align=center>24T </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">248 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 3/4 </TD></TR><TR><TD align=center>25 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>26 </TD><TD align=center bgcolor="#ffff80">208 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">197 </TD><TD align=center bgcolor="#80ffff">8 3/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">7 3/4 </TD></TR><TR><TD align=center>26R </TD><TD align=center bgcolor="#ffff80">208 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">197 </TD><TD align=center bgcolor="#80ffff">8 3/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">7 3/4 </TD></TR><TR><TD align=center>27 </TD><TD align=center bgcolor="#ffff80">306 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">12 1/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>27F </TD><TD align=center bgcolor="#ffff80">318 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">227 </TD><TD align=center bgcolor="#80ffff">12 1/2 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 15/16 </TD></TR><TR><TD align=center>27H </TD><TD align=center bgcolor="#ffff80">298 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">235 </TD><TD align=center bgcolor="#80ffff">11 3/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 1/4 </TD></TR><TR><TD align=center>29NF </TD><TD align=center bgcolor="#ffff80">330 </TD><TD align=center bgcolor="#ffff80">140 </TD><TD align=center bgcolor="#ffff80">227 </TD><TD align=center bgcolor="#80ffff">13 </TD><TD align=center bgcolor="#80ffff">5 1/2 </TD><TD align=center bgcolor="#80ffff">8 15/16 </TD></TR><TR><TD align=center>33 </TD><TD align=center bgcolor="#ffff80">338 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#80ffff">13 5/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD></TR><TR><TD align=center>34 </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">200 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">7 7/8 </TD></TR><TR><TD align=center>34R </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">200 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">7 7/8 </TD></TR><TR><TD align=center>35 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>36R </TD><TD align=center bgcolor="#ffff80">263 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">206 </TD><TD align=center bgcolor="#80ffff">10 3/8 </TD><TD align=center bgcolor="#80ffff">7 1/4 </TD><TD align=center bgcolor="#80ffff">8 1/8 </TD></TR><TR><TD align=center>40R </TD><TD align=center bgcolor="#ffff80">277 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">10 15/16</TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>41 </TD><TD align=center bgcolor="#ffff80">293 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">11 3/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>42 </TD><TD align=center bgcolor="#ffff80">243 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#80ffff">9 5/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">6 13/16</TD></TR><TR><TD align=center>43 </TD><TD align=center bgcolor="#ffff80">334 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">205 </TD><TD align=center bgcolor="#80ffff">13 1/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">8 1/16 </TD></TR><TR><TD align=center>45 </TD><TD align=center bgcolor="#ffff80">240 </TD><TD align=center bgcolor="#ffff80">140 </TD><TD align=center bgcolor="#ffff80">227 </TD><TD align=center bgcolor="#80ffff">9 7/16 </TD><TD align=center bgcolor="#80ffff">5 1/2 </TD><TD align=center bgcolor="#80ffff">8 15/16 </TD></TR><TR><TD align=center>46 </TD><TD align=center bgcolor="#ffff80">273 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#80ffff">10 3/4 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 </TD></TR><TR><TD align=center>47 </TD><TD align=center bgcolor="#ffff80">246 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">190 </TD><TD align=center bgcolor="#80ffff">9 11/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 1/2 </TD></TR><TR><TD align=center>48 </TD><TD align=center bgcolor="#ffff80">306 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">192 </TD><TD align=center bgcolor="#80ffff">12 1/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 9/16 </TD></TR><TR><TD align=center>49 </TD><TD align=center bgcolor="#ffff80">381 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">192 </TD><TD align=center bgcolor="#80ffff">15 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD></TR><TR><TD align=center>50 </TD><TD align=center bgcolor="#ffff80">343 </TD><TD align=center bgcolor="#ffff80">127 </TD><TD align=center bgcolor="#ffff80">254 </TD><TD align=center bgcolor="#80ffff">13 1/2 </TD><TD align=center bgcolor="#80ffff">5 </TD><TD align=center bgcolor="#80ffff">10 </TD></TR><TR><TD align=center>51 </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#ffff80">129 </TD><TD align=center bgcolor="#ffff80">223 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD><TD align=center bgcolor="#80ffff">5 1/16 </TD><TD align=center bgcolor="#80ffff">8 13/16 </TD></TR><TR><TD align=center>51R </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#ffff80">129 </TD><TD align=center bgcolor="#ffff80">223 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD><TD align=center bgcolor="#80ffff">5 1/16 </TD><TD align=center bgcolor="#80ffff">8 13/16 </TD></TR><TR><TD align=center>52 </TD><TD align=center bgcolor="#ffff80">186 </TD><TD align=center bgcolor="#ffff80">147 </TD><TD align=center bgcolor="#ffff80">210 </TD><TD align=center bgcolor="#80ffff">7 5/16 </TD><TD align=center bgcolor="#80ffff">5 13/16 </TD><TD align=center bgcolor="#80ffff">8 1/4 </TD></TR><TR><TD align=center>53 </TD><TD align=center bgcolor="#ffff80">330 </TD><TD align=center bgcolor="#ffff80">119 </TD><TD align=center bgcolor="#ffff80">210 </TD><TD align=center bgcolor="#80ffff">13 </TD><TD align=center bgcolor="#80ffff">4 11/16 </TD><TD align=center bgcolor="#80ffff">8 1/4 </TD></TR><TR><TD align=center>54 </TD><TD align=center bgcolor="#ffff80">186 </TD><TD align=center bgcolor="#ffff80">154 </TD><TD align=center bgcolor="#ffff80">212 </TD><TD align=center bgcolor="#80ffff">7 5/16 </TD><TD align=center bgcolor="#80ffff">6 1/16 </TD><TD align=center bgcolor="#80ffff">8 3/8 </TD></TR><TR><TD align=center>55 </TD><TD align=center bgcolor="#ffff80">218 </TD><TD align=center bgcolor="#ffff80">154 </TD><TD align=center bgcolor="#ffff80">212 </TD><TD align=center bgcolor="#80ffff">8 5/8 </TD><TD align=center bgcolor="#80ffff">6 1/16 </TD><TD align=center bgcolor="#80ffff">8 3/8 </TD></TR><TR><TD align=center>56 </TD><TD align=center bgcolor="#ffff80">254 </TD><TD align=center bgcolor="#ffff80">154 </TD><TD align=center bgcolor="#ffff80">212 </TD><TD align=center bgcolor="#80ffff">10 </TD><TD align=center bgcolor="#80ffff">6 1/16 </TD><TD align=center bgcolor="#80ffff">8 3/8 </TD></TR><TR><TD align=center>57 </TD><TD align=center bgcolor="#ffff80">205 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">177 </TD><TD align=center bgcolor="#80ffff">8 1/16 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD><TD align=center bgcolor="#80ffff">6 15/16 </TD></TR><TR><TD align=center>58 </TD><TD align=center bgcolor="#ffff80">255 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">177 </TD><TD align=center bgcolor="#80ffff">10 1/16 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD><TD align=center bgcolor="#80ffff">6 15/16 </TD></TR><TR><TD align=center>58R </TD><TD align=center bgcolor="#ffff80">255 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">177 </TD><TD align=center bgcolor="#80ffff">10 1/16 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD><TD align=center bgcolor="#80ffff">6 15/16 </TD></TR><TR><TD align=center>59 </TD><TD align=center bgcolor="#ffff80">255 </TD><TD align=center bgcolor="#ffff80">193 </TD><TD align=center bgcolor="#ffff80">196 </TD><TD align=center bgcolor="#80ffff">10 1/16 </TD><TD align=center bgcolor="#80ffff">7 5/8 </TD><TD align=center bgcolor="#80ffff">7 3/4 </TD></TR><TR><TD align=center>60 </TD><TD align=center bgcolor="#ffff80">332 </TD><TD align=center bgcolor="#ffff80">160 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">13 1/16 </TD><TD align=center bgcolor="#80ffff">6 5/16 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>61 </TD><TD align=center bgcolor="#ffff80">192 </TD><TD align=center bgcolor="#ffff80">162 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">7 9/16 </TD><TD align=center bgcolor="#80ffff">6 3/8 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>62 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#ffff80">162 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD><TD align=center bgcolor="#80ffff">6 3/8 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>63 </TD><TD align=center bgcolor="#ffff80">258 </TD><TD align=center bgcolor="#ffff80">162 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">10 3/16 </TD><TD align=center bgcolor="#80ffff">6 3/8 </TD><TD align=center bgcolor="#80ffff">8 7/8 </TD></TR><TR><TD align=center>64 </TD><TD align=center bgcolor="#ffff80">296 </TD><TD align=center bgcolor="#ffff80">162 </TD><TD align=center bgcolor="#ffff80">225 </TD><TD align=center bgcolor="#80ffff">11 11/16</TD><TD align=center bgcolor="#80ffff">6 3/8 </TD><TD align=center bgcolor="#80ffff">8 7/8</TD></TR><TR><TD align=center>65 </TD><TD align=center bgcolor="#ffff80">306 </TD><TD align=center bgcolor="#ffff80">190 </TD><TD align=center bgcolor="#ffff80">192 </TD><TD align=center bgcolor="#80ffff">12 1/16 </TD><TD align=center bgcolor="#80ffff">7 1/2 </TD><TD align=center bgcolor="#80ffff">7 9/16 </TD></TR><TR><TD align=center>70 </TD><TD align=center bgcolor="#ffff80">208 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">196 </TD><TD align=center bgcolor="#80ffff">8 3/16 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">7 11/16 </TD></TR><TR><TD align=center>71 </TD><TD align=center bgcolor="#ffff80">208 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">216 </TD><TD align=center bgcolor="#80ffff">8 3/16 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">8 1/2 </TD></TR><TR><TD align=center>72 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">210 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">8 1/4 </TD></TR><TR><TD align=center>73 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">216 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">8 1/2 </TD></TR><TR><TD align=center>74 </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">184 </TD><TD align=center bgcolor="#ffff80">222 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">7 1/4 </TD><TD align=center bgcolor="#80ffff">8 3/4 </TD></TR><TR><TD align=center>75 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">196 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">7 11/16 </TD></TR><TR><TD align=center>76 </TD><TD align=center bgcolor="#ffff80">334 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">216 </TD><TD align=center bgcolor="#80ffff">13 1/8 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">8 1/2 </TD></TR><TR><TD align=center>78 </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#ffff80">179 </TD><TD align=center bgcolor="#ffff80">196 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD><TD align=center bgcolor="#80ffff">7 1/16 </TD><TD align=center bgcolor="#80ffff">7 11/16 </TD></TR><TR><TD align=center>85 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">203 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 </TD></TR><TR><TD align=center>86 </TD><TD align=center bgcolor="#ffff80">230 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">203 </TD><TD align=center bgcolor="#80ffff">9 1/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">8 </TD></TR><TR><TD align=center>90 </TD><TD align=center bgcolor="#ffff80">246 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">9 11/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>91 </TD><TD align=center bgcolor="#ffff80">280 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">11 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>92 </TD><TD align=center bgcolor="#ffff80">317 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">12 1/2 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>93 </TD><TD align=center bgcolor="#ffff80">354 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">15 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>95R </TD><TD align=center bgcolor="#ffff80">394 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">190 </TD><TD align=center bgcolor="#80ffff">15 9/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 1/2 </TD></TR><TR><TD align=center>96R </TD><TD align=center bgcolor="#ffff80">242 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#80ffff">9 9/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD></TR><TR><TD align=center>97R </TD><TD align=center bgcolor="#ffff80">252 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">190 </TD><TD align=center bgcolor="#80ffff">9 15/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 1/2 </TD></TR><TR><TD align=center>98R </TD><TD align=center bgcolor="#ffff80">283 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">190 </TD><TD align=center bgcolor="#80ffff">11 3/16 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">7 1/2 </TD></TR><TR BGCOLOR="#C0C0C0"><TD ALIGN=center COLSPAN=7>PASSENGER CAR AND LIGHT COMMERCIAL BATTERIES6-VOLT(3 CELLS) </TD></TR><TR><TD align=center>1 </TD><TD align=center bgcolor="#ffff80">232 </TD><TD align=center bgcolor="#ffff80">181 </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#80ffff">9 1/8 </TD><TD align=center bgcolor="#80ffff">7 1/8 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD></TR><TR><TD align=center>2 </TD><TD align=center bgcolor="#ffff80">264 </TD><TD align=center bgcolor="#ffff80">181 </TD><TD align=center bgcolor="#ffff80">238 </TD><TD align=center bgcolor="#80ffff">10 3/8 </TD><TD align=center bgcolor="#80ffff">7 1/8 </TD><TD align=center bgcolor="#80ffff">9 3/8 </TD></TR><TR><TD align=center>2E </TD><TD align=center bgcolor="#ffff80">492 </TD><TD align=center bgcolor="#ffff80">105 </TD><TD align=center bgcolor="#ffff80">232 </TD><TD align=center bgcolor="#80ffff">19 7/16 </TD><TD align=center bgcolor="#80ffff">4 1/8 </TD><TD align=center bgcolor="#80ffff">9 1/8 </TD></TR><TR><TD align=center>2N </TD><TD align=center bgcolor="#ffff80">254 </TD><TD align=center bgcolor="#ffff80">141 </TD><TD align=center bgcolor="#ffff80">227 </TD><TD align=center bgcolor="#80ffff">10 </TD><TD align=center bgcolor="#80ffff">5 9/16 </TD><TD align=center bgcolor="#80ffff">8 15/16 </TD></TR><TR><TD align=center>17HF </TD><TD align=center bgcolor="#ffff80">187 </TD><TD align=center bgcolor="#ffff80">175 </TD><TD align=center bgcolor="#ffff80">229 </TD><TD align=center bgcolor="#80ffff">7 3/8 </TD><TD align=center bgcolor="#80ffff">6 7/8 </TD><TD align=center bgcolor="#80ffff">9 </TD></TR><TR BGCOLOR="#C0C0C0"><TD ALIGN=center COLSPAN=7>HEAVY-DUTY COMMERCIAL BATTERIES 12-VOLT (6 CELLS)</TD></TR><TR><TD align=center>4D </TD><TD align=center bgcolor="#ffff80">527 </TD><TD align=center bgcolor="#ffff80">222 </TD><TD align=center bgcolor="#ffff80">250 </TD><TD align=center bgcolor="#80ffff">20 3/4 </TD><TD align=center bgcolor="#80ffff">8 3/4 </TD><TD align=center bgcolor="#80ffff">9 7/8 </TD></TR><TR><TD align=center>6D </TD><TD align=center bgcolor="#ffff80">527 </TD><TD align=center bgcolor="#ffff80">254 </TD><TD align=center bgcolor="#ffff80">260 </TD><TD align=center bgcolor="#80ffff">20 3/4 </TD><TD align=center bgcolor="#80ffff">10 </TD><TD align=center bgcolor="#80ffff">10 1/4 </TD></TR><TR><TD align=center>8D </TD><TD align=center bgcolor="#ffff80">527 </TD><TD align=center bgcolor="#ffff80">283 </TD><TD align=center bgcolor="#ffff80">250 </TD><TD align=center bgcolor="#80ffff">20 3/4 </TD><TD align=center bgcolor="#80ffff">11 1/8 </TD><TD align=center bgcolor="#80ffff">9 7/8 </TD></TR><TR><TD align=center>28 </TD><TD align=center bgcolor="#ffff80">261 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">240 </TD><TD align=center bgcolor="#80ffff">10 5/16 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 7/16 </TD></TR><TR><TD align=center>29H </TD><TD align=center bgcolor="#ffff80">334 </TD><TD align=center bgcolor="#ffff80">171 </TD><TD align=center bgcolor="#ffff80">232 </TD><TD align=center bgcolor="#80ffff">13 1/8 </TD><TD align=center bgcolor="#80ffff">6 3/4 </TD><TD align=center bgcolor="#80ffff">9 1/8 10 </TD></TR><TR><TD align=center>30H </TD><TD align=center bgcolor="#ffff80">343 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">235 </TD><TD align=center bgcolor="#80ffff">13 1/2 </TD><TD align=center bgcolor="#80ffff">6 13/16 </TD><TD align=center bgcolor="#80ffff">9 1/4 10 </TD></TR><TR><TD align=center>31 </TD><TD align=center bgcolor="#ffff80">330 </TD><TD align=center bgcolor="#ffff80">173 </TD><TD align=center bgcolor="#ffff80">240 </TD><TD align=center bgcolor="#80ffff">13 </TD><TD align=center bgcolor="#80ffff">6 13/18 </TD><TD align=center bgcolor="#80ffff">9 7/16 </TD></TR><TR><TD align=center></TD><TD align=center bgcolor="#ffff80"></TD><TD align=center bgcolor="#ffff80"></TD><TD align=center bgcolor="#ffff80"></TD><TD align=center bgcolor="#80ffff"></TD><TD align=center bgcolor="#80ffff"></TD><TD align=center bgcolor="#80ffff"></TD></TR><TR BGCOLOR="#C0C0C0"><TD ALIGN=center COLSPAN=7>ELECTRIC VEHICLE BATTERIES 6-VOLT (3CELLS)</TD></TR><TR><TD align=center>GC2 </TD><TD align=center bgcolor="#ffff80">264 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">270 </TD><TD align=center bgcolor="#80ffff">10 3/8 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD><TD align=center bgcolor="#80ffff">10 5/8 </TD></TR><TR><TD align=center>GC2H </TD><TD align=center bgcolor="#ffff80">264 </TD><TD align=center bgcolor="#ffff80">183 </TD><TD align=center bgcolor="#ffff80">295 </TD><TD align=center bgcolor="#80ffff">10 3/8 </TD><TD align=center bgcolor="#80ffff">7 3/16 </TD><TD align=center bgcolor="#80ffff">11 5/8 </TD></TR></TABLE>

<CENTER>Data excerpted from the BCI Battery Replacement Data Book.
[ errors may have been introduced in transcription. ]</CENTER>

<B>Note 1</B>: The complete BCI listing includes
several categories not included here: Heavy-Duty motor Coach and Bus batteries,
and Special Tractor Batteries (6 and 12-volt). BCI provides configuration
diagrams and performance ratings as well. Contact BCI, 401 N. Michigan
ave, Chicago IL 60611-4267, (312) 644-6610 for more information.

<B>Note 2: </B>The maximum height includes the terminal
posts. Width and length measurements are generally to the widest point,
including protruding flanges, except for hold-down flanges at the bottom
of the battery. See the diagrams in the BCI battery Replacement Data Book
for full details.

 

[Reata]

Okki, you should really look at the group 31 in the same Sears platinum version. It will fit in their with no mods and no extensions of the wires. It is a huge super-battery and will easily last 6-7 years. Just my $0.02,

Reata

 

[Okki]

Okki, you should really look at the group 31 in the same Sears platinum version. It will fit in their with no mods and no extensions of the wires. It is a huge super-battery and will easily last 6-7 years. Just my $0.02,

Reata

*grin* .. you mean this bad-boy?

From what I've seen on here it does require some re-bending of connectors. In this thread you read all about what I'm trying to do before installing the Group 31. The 35D is just a temp fix.
http://www.toyota-4runner.org/5th-g...ble-between-battery-fuse-box.html#post1548936

Okki

 

[limamike]

LOL .... nope.. haven't given up yet on the wire exchange :juggle: Just want to keep things running smooth while I figure it out. Hope to get a bit closer again this weekend as I should have some time to puzzle. Will install the 35D when things go back together. Going to focus on separating the fuse box this weekend since I'm pretty sure I know who/where the cables run to/from the alternator (Yes [MENTION=62008]limamike[/MENTION].. I still need to draw a line diagram. Been out of country, but will do that today or this weekend as well).

Excuses excuses, Paul! :llama:

 

[Ducmonsta]

Speaking of excuses [MENTION=62008]limamike[/MENTION]. How's the trip planning coming? :yo:
http://www.toyota-4runner.org/5th-gen-t4rs/155938-fj-summit-2014-a-3.html#post1565859

Sorry for the hi-jack, Okki.

 

[limamike]

Speaking of excuses [MENTION=62008]limamike[/MENTION]. How's the trip planning coming? :yo:
http://www.toyota-4runner.org/5th-gen-t4rs/155938-fj-summit-2014-a-3.html#post1565859

Sorry for the hi-jack, Okki.

Why you gotta do me like that, Bobby? :shrug:

 

[Okki]

Replacing the cables between the Battery, Alternator and Fusebox

Replacement of Aternator Wires
As I started looking into installing a Diehard Platinum Group 31M into my 4Runner, I thought I would install larger gauge wires running from the alternator to the battery and fusebox. The longer wires would enable slightly easier installation of the group 31M battery, and the larger gauge would get me set up for better current transfer if I ever upgrade to a higher output alternator.

Originally I thought this would be as “simple” as replacing the power cable between the alternator and the battery, the power cable between the battery and the fusebox, ground from the battery to the fender and a ground cable that runs from the battery to somewhere around the alternator.
The basic layout of the cables is as indicated in the image below. Red are power cables and blue ground. I’ve indicated where the detail pictures are roughly located.

PIC 0
The basic path of the power and ground cable is pretty straight forward. There is a short cable that connects from the battery to the BOTTOM section of the fusebox. This cable ended up being the biggest problem and the reason I did not complete this modification.

The fusebox top and bottom section are held together by multiple overlapping clips. On each location you first have to undo the clip that holds the second clip and then the second clip that holds the 2 sections together. There are the following clips:

• 3 on the side of the headlight.
• 3 on the firewall side (one hidden behind the smaller fusebox that attached to the main fusebox).
• 1 small one on the engine side.
• 2 on the fender side (you have to undo the wto bolts holding the fusebox and several cable clamps to get some sort of access to these 2 clips).

All the power and ground cables are held in place by a bracket with a cable guide inside some corrugated split loom. It’s easiest to unbolt the bracket from the inner fender and then release the cable guide from the back with a small screwdriver.

PIC 1
In the picture below you can see the cables going into the split loom, through the cable guide and into a larger cable guide that is at the bottom of the alternator. The cable guide on the alternator is held on by 2 bolts. With the battery out of the way there is fairly easy access to the first bolt (radiator side) but the second bolt (firewall side) is harder to get to and requires some fiddling with a small wrench.

PIC 2
You can see the radiator side bolt in this picture. A small socket makes quick work of this one. I’m pretty sure there are some clips on the cable guide assembly, but I did not open it up once I had it separated from the alternator. The cable group splits here with the power going up to the alternator terminal and the ground going on to a second guide.

PIC 3
The power cable goes up and makes a sharp turn to the alternator terminal. Under the cap is a large terminal end. There are little clips on each side of the cap that will allow the cap to swing up and provide access to the terminal nut.

PIC 4
The ground cable continuous on to a location further back under the drivetrain (transmission). There is a second cable guide and the cable loom is wrapped in heat reflecting tape.

PIC 5
At this point I’m not entirely clear if there is a second ground cable joining from elsewhere or if the calbe splits, but there is another cap protected end point and a more traditional ground end point. The problem with the “traditional” end point is that there is a second smaller cable that terminates there as well and I’m not sure where that originates from.

Conclusion
While I think it’s possible to complete the cable exchange, it is an amount of work and truck disassembly that I cannot complete on a weekend and since it’s my daily driver, that’s a pretty big deal to me. Also the work involved with the fusebox is significant and possibly resulting in a $180 replacement fusebox and all the associated headaches that come with that.

In the image below you are separating 1 from 5.

For the thread on my other experiences with this project, please go here: http://www.toyota-4runner.org/5th-g...e-between-battery-fuse-box-3.html#post1555766

Okki

 

[Okki]

Diehard Platinum Group 31M Battery in OEM Main Location

Diehard Platinum Group 31M Battery in OEM Main Location

Description:
Item # 02850131000P Model # 50131
The DieHard Marine Battery Size 31m has tin-coated brass terminals and 99.99 percent pure virgin lead plates, that make it durable, powerful and reliable. Safety first design features a non-spillable and sealed design with an Absorbed Glass Mat construction. These glass mats are instrumental in keeping the acid in place to make the battery vibration-resistant and easy to mount. Sail away on a sunny day or as the rain lashes at the shores with this weather-resistant battery.

Maintenance-free this Group Size 31m battery is ideal for use on your recreational marine vehicle
Features 1150 CCA that delivers quick ignition
Container is made from high-quality polycarbonate/polyester
Has a long off-season storage power and a reserve power of 205 minutes
An AGM construction offers the battery longevity and mounting flexibility
The battery is vibration-resistant and sports a military-grade construction
Item Weight: 75 lbs.
Dimensions: 13"(L) x 6.8"(W) x 9.5"(H)
Three-year free replacement limited manufacturer's warranty

Specifications:
Dimensions:
Height (in.): 9.5
Item Weight (lbs.): 75
Length (in.): 13
Width (in.): 6.8
Battery Type:
Group Size: 31M
Power Configuration:
Number of Cells: 6
Power Ratings:
Amp Hours at 20 Hour Rate: 100
Capacity Amp Hours at 10 Hour Rating: 92
Cold Cranking Amps (CCA at 0 deg.F): 1150
Reserve Capacity (RC): 205 min.
Design & Construction:
Battery Design:Absorbed Glass Mat
Container Material: Polycarbonate/polyester
Maintenance: Maintenance Free
Overall Type: Deep-cycle
Temperate Zone: North or South
Positive Terminal Side: Right
Terminal Post Location: Top
Warranties & Coverage:
Free Replacement Warranty Term: 36 months

NOTES
It is important to note that the Diehard Group 31M has 2 DIFFERENT SIZE terminal posts.
POSITIVE: 3/8-16 : This will fit a normal Fleet Terminal.
NEGATIVE: 5/16-18 : This will need a shim to fit a Fleet Terminal

Parts:
Diehard Platinum Group 31M, $231, Sears
Fleet Terminal (AC166), ~$12, Advance Auto Parts
Fleet Terminal (AC166), ~$2.5, Advance Auto Parts

Installation:
The Group 31M fits in the OEM Main Battery location with only a few modifications to the terminal ends. The L-shaped cable ends need to be flattened out in order for them to clear the battery. Because the fleet terminals stick out a little more I felt that made things a tad easier as well.

I used my hydraulic crimper to flatten out the cable ends. This was relatively easy to manage by one person and created flatter ends than I would have been able to achieve by using pliers.

You also will need to flatten out one of the little wings on the positive cable so it can be connected to the fleet terminal.

With the cable ends adjusted, you can now place the battery. The OEM plastic battery tray won't fit the battery, so you'll either have to upgrade to an aftermarket universal tray or battery cage. You can install it without, but you have a higher risk of the battery twisting under the battery tie-down.

The positive wires hooked up to the fleet terminal.

The negative (ground) wires hooked up to the fleet terminal (using a post shim):

I used a large screwdriver to emboss the minus sign into the shim.

Once fully tied down, your end result should look something like this:

Make sure you check your suspension measurement, because the Group 31M is significantly heavier than the OEM battery. I had to crank my adjustable coil quite a bit for it to match the passenger side lift once again.

Also, take a picture of your radio settings (stations etc) before you disconnect the old battery, because you will have to reset everything. Having a picture of the various screens will allow you to set your stations quickly and efficiently.

Lastly, write on your battery with a sharpie when you installed it. Makes it easy for both replacement and possible warranty information.

EDIT:
You can buy terminal studs for the threaded posts here: Stud to Post Conversion Adapters - Remy Battery
Make sure you get one each of the following sizes: 5/16-18 and 3/8-16.

Okki

 

[IronManKansas]

Did you put the 14x22 on the main back seats and the 12x22 in the middle?
14*22
12*22
14*22

thanks

 

[Okki]

Did you put the 14x22 on the main back seats and the 12x22 in the middle?
14*22
12*22
14*22

thanks

Correct, although I'm still running the 12*22 on the passenger seat and haven't switched it to the center yet.

Okki

 

[Okki]

Adventure Tool Company (ATC) Shop Roll

Adventure Tool Company (ATC) Shop Roll
Price: $89.99
ShopRoll Tool Roll - Adventure Tool Company

I picked up an ATC shop Roll at the Overland Expo West and just got around to starting a tool list for it and getting it stocked up.

To date I had all my tools for the 4Runner is a bag that I got at the 2012 FJ Summit and while that worked fine, since it was a basic dump bag, it's always hard to find stuff in it.

I looked through all my Shrockworks installation lists and added items to it that I know I have used while working on my truck. Now that I have a piece of paper with everything listed on it, I can easily add to it or adjust as my experience changes.

As it currently stands, the roll is not fully loaded out, but until the wife allows money back in the play-fund, I will simply use the list to load out the remainder from my main tool chest before we head out on a trip.

Okki

 

[safetymike]

Has anyone tried this mod with the new ARB Breather Kit ? I have one on order and it appears from the ARB Info that it should work. Thanks for the post Okki !

 

[Okki]

Has anyone tried this mod with the new ARB Breather Kit ? I have one on order and it appears from the ARB Info that it should work. Thanks for the post Okki !

Took a quick glance at the ARB kit, and I didn't see any obvious connectors for the diff., but I'm on my phone and it's hard to compare my part list to the parts in the kit. However it looks nicely put together. The 4 port manifold is nice and the flat filter is a nice space saver.

I would probably have given this kit a try if I hadn't done the mod yet.

Okki

EDIT : looks like the diff union is not in kit. Also not sure if the diff union works with the 8mm hose in the kit. Check the union specs and convert as needed.

 

[Okki]

Rear Attachment Adjustment (for Icon Billet Trailing Arms)

Problem: When stuffing the rear wheels, a grease port on the billet trailing arms can make contact with a piece of metal from the rear links.

Cost: $0.-

Illustration of very tight clearance.

You can actually see where the metal has worn away a bit from making contact.

The Fix:
Take all proper precautions when operating your hi-lift!. You will have to lift the truck on each side in order to make room for your pry-bar.

Carefully insert the pry-bar (wrap the end with tape to minimize damage to your billet parts) in the space between the trailing arm and axle link.

Press up and down on the pry-bar to bend out the metal tab.

It doesn't take much and you will not hear the occasional "ping" anymore as you pull into a steep driveway or over a boulder. The metal tab should have a more rounded profile now, providing plenty of clearance.

Took me about 15 minutes to get the hi-lift down and both sides bent out.

Okki

 

[Desert Fox]

When my wife tells me I drank too much Captain Morgan, I am going to have her read your post on installing the Diehard. OMG, that is the most detailed write up that i got so lost in. It was like watching Clockwork Orange

 

[Okki]

When my wife tells me I drank too much Captain Morgan, I am going to have her read your post on installing the Diehard. OMG, that is the most detailed write up that i got so lost in. It was like watching Clockwork Orange

Considering that "Clockwork Orange" is a cult classic, I'll take that as a compliment! :lol:

Now pay attention and keep reading!

Okki

 

[2014 Warthog]

Problem: When stuffing the rear wheels, a grease port on the billet trailing arms can make contact with a piece of metal from the rear links.
Okki

Yeah I noticed that when I installed mine. Used a flat jaw pipe wrench to bend that part up.

Kind of strange, instructions should have mentioned it specifically I think.

 

[hendooman]

Okki, followed your Gobi install, thanks for the write up. In regards to the fairing I got mine to touch the roof almost the whole way around, just a tad off the paint on the ends.

Question for you. hows your wind noise? It still seems pretty bad. I think a fairing for the upper bar might need to be fabed up.

 

[cd121082]

I mounted an auxiliary fuse box to power the roof lights that I have on my Gobi Stealth Rack, but also so that I would have everything in place for any additional lights I may want to mount and a compressor.

Lets start with the boring stuff. Below are the electrical schematics and the drawings for the brackets I fabricated.

Fuse Box Bracket:

Relay Bracket:

I fabricated the brackets out of sheet aluminum that I picked up at Lowes.

I ordered all the surrounds and switches from Over The River And Throw The Woods (www.otrattw.com):
Product ID: V1D1J66B-AFCN5-17U
Product Name: V-Series Contura II sealed rocker switch, Driving Lights
Quantity: 1
Unit Price: $12.00
--------------------------
Product ID: V1D1J66B-AYC9A-CP1
Product Name: V-series Contura II sealed rocker switch, Compressor
Quantity: 1
Unit Price: $12.00
--------------------------
Product ID: V1D1J66B-AFCM4-RF1
Product Name: V-Series Contura II sealed rocker switch, Roof Lights
Quantity: 1
Unit Price: $12.30
--------------------------
Product ID: V1D1J66B-AFC77-18B
Product Name: V-Series Contura II sealed rocker switch, Backup Lights
Quantity: 1
Unit Price: $12.30
--------------------------
Product ID: VMS-01
Product Name: Snap-In Single Switch Holder
Quantity: 1
Unit Price: $1.75
--------------------------
Product ID: VM3-01
Product Name: Snap-In Three Position Switch Holder
Quantity: 1
Unit Price: $5.30
--------------------------
Product ID: 5025B
Product Name: Blue Seas ST Blade Fuse Block With Cover
Quantity: 1
Unit Price: $27.95
--------------------------

Please not that these switches DO NOT FIT IN THE OEM SLOTS! You need to enlarge the locations (taller) or cut a big hole and use the snap in panel like I did.

The fusebox is connected to the battery using 8 gauge stranded wire. On the battery side you can use 8 gauge copper lugs, but on the high-voltage relay side I had to use 6 gauge lugs because I needed a 3/8 hole. I cut a T-shape in the top of the lug so I could properly compress the lug around the wire.

Make sure you leave enough room on either side of the brackets so you have room for the terminals to come off the fuse box.

On the fender wall you can use existing threaded holes to secure the bracket. When you have the bracket bent in the right shape, place 2 pieces of painters tape on the fender wall, one covering each hole. mark the hole on the take with pencil. Pull back partially, place the bracket and stick the tape back. remove the bracket with the tape in place and drill the mounting holes accordingly.

I used an existing hole in the firewall to run cable guide and wires.

I used a hobby knife to cut through the insulation and rubber backing that is inside the driver footwell. I started the cutting from the engine bay so you know the exact location to trim your hole.

This is the view inside the driver foot well;

I have a total of 8 wires running through this passage.

A second bracket provides a mounting spot for an additional 3 relays (or other items) and reinforces the fusebox bracket.

In the final installation I used Allen bolts.

To the left of the bracket you can see the Stinger SGP38 High Voltage relay. It was mounted using two threaded holes that already existed in the wheel well. they are shallow holes, but provide enough threads to hold the relay securely in place.

As mentioned, I needed to modify 2 6 gauge copper lugs with 3/8 hole in order to connect to the terminals on the relay.

I fabricated a wiring harness from the harness that came with my Hella lights, but any 16 or 18 gauge wire will do.

Black = ground
Yellow = Dashboard light; spliced into RSCA switch green wire
Red = 12 volt accessory switched; use add-a-circuit on P/Outlet mini fuse or splice into appropriate wire.
Green (not shown) = Switch to relay

Hook up the switches and you are good to go!

Man this is so sweet. I have to lights on my grill gaurd and the wires are just a mess in the engine bay. I will probably do what you did to get those KC light wiring kits in order. dont be surprised is i dont bug you about those brackets. Did you have someone make them for you?