Figured I'd post mine here. When I started this build 3 years ago, I selected a single battery setup (Odyssey 31M) for simplicity. Didn't really have time to clean things up really before installing last-minute stuff ahead of trips. It quickly turned into a rat's nest of wiring, although everything was sealed and crimped properly. Cleaned it up a couple months ago ahead of my Baja trip.
Previously I had flattened cables to get them to reach the further posts on the Odyssey battery, now cleaned up with Slee extenders. Still running the Bussman RTMR as I still prefer relays/fuses for circuit protection over electronic controls/capacitors/circuit boards (like the sPod and Switch Pros).
- Odyssey Group 31 (PC2150)
- Slee Terminal Extenders
- Blue Sea HD Battery Disconnect (rated for 600a continuous, 900a intermittent): this is my in-line winch disconnect in case of a winch solenoid stuck open. I've seen people use regular battery connectors or a high amp solenoid. Most are not rated for the amp rating of the winch.
- Upgraded factory Warn winch wiring from 2AWG (very undersized for current load) to 1/0AWG to match power draw
- Blue Sea 300A 4-post power bussbar: this eliminated all the power wires that previously hung off the terminals that need a direct power source and cannot run off the relay box. Most of the high amp circuits are now separately fused through this connection: (2) 40A circuits to the ARB compressor, (1) 40A circuit to a 4AWG direct to my internal Blue Sea fuse box in the rear cargo area (powers fridge, HAM radio, and some other in-cabin electrical accessories). Also have a National Luna single battery monitor/alarm in the back.
- Blue Sea 80A circuit breaker: Protects the 300A bussbar circuit and the Bussman RTMR relay box from overloading. Technically the 300A Bussbar has double failsafes (the circuit breaker and the individual high-amp fuses in each circuit).
- Bussmann RTMR circuit box: All circuits are on a relay: rock lighting, light bars, air compressor, etc.)
- Everything wrapped in Raychem DR-25 milspec sleeving in the engine bay, terminals with double layer heat shrink for added protection from the elements. This is heat, chemical, and corrosion resistant and way better than that split loom plastic sleeving at the auto parts store. Everything in the cabin is wrapped in PET sleeving.
- Battery is protected via alarms and fridge low-voltage cutoff (really the fridge is the only thing that's running while the engine is off), supplemented by a high voltage charging diode to properly charge the battery and also solar power.
BEFORE:
AFTER:
