Installing A Dual Battery Setup In My 1993 FZJ80 Landcruiser

In setting up my FZJ80 for long range, self sufficent, expedition traveling, i knew that the addition of my 40qt Norcold/ARB Fridge and 1500 Watt Vector Power Inverter was going to require an Aux battery setup.  I didnt want to risk damaging my starting battery and getting stranded!

I  wanted to install an aux battery to use for my accesories instead of possibly damaging my main battery.  I decided to go with a very simple dual battery setup and add a deep cycle marine battery for my accesories to draw from.  I want to set this up so that the accesories ONLY draw from the aux battery and never mess with the charge on my starting battery.  I think this is the safest way to do this.  I do not like some of the other designs that draw from both and possibly killing both batteries!  Defeats the whole purpose of this mod!

There are many writeups about installing the actually battery into the rig via the early style battery tray and how to relocate the windshield washer bottle, so i wont repeat on that.  Check these sites for info on that:

First off, one thing i didnt really notice in anyones writeup is the removal and rerouting of the resonator and the hose!  There is a hose resonator/silencer that needs to be removed for the 2nd battery to fit.  

The hose and resonator circled in green needs to be removed and a hose needs to be run where the red arrow is.  I used Napa hose Part # 9260 and it worked like a charm with a little trimming.  The ends are 2 different sizes, so you need to get creative on one side.  I just used some pieces of innertube to make up the difference.  With this resonator removed, it is a tad louder @ idle but nothing to worry about.

Here is a BEFORE pic (click to enlarge);

Here is an AFTER (not my rig, but you get the point)pic (click to enlarge)

Luckily, a very simple and straight forward diagram/schematic is included with the BlueSeas 4 Way Switch is exactly what i wanted.  

I decided to use a very simple manual switching design as opposed to the automatic ones with relays and isolators and such.  I want to keep my rig as simple as possible to make it easier to diagnos any problems when out in the middle of no where!  Boats have been using this setup successfully for years!

My Parts List

STILL LEFT TO DO: INSTALL FUSES AND COVER ALL + TERMINALS

Some Random Pics

(click pics to enlarge)

Positive Distribution Block	Positive Distribution Block With Loom Protector Installed	Overall Pic Before Loom Protector
Blue Seas 4 Way Switch	Blue Seas 4 Way Switch Finished Install	Military Spec Terminals
Before Loom Pic	Final Install	All Cables Wrapped In Loom Protector
Slee Washer Bottle Relocation Kit!  Doesnt fit all that well so some tweaking was needed!

     The Purpose of installing the Aux battery was to run a fridge/freezer and a 1500Watt inverter to run or recharge items while camping.  Here are the preliminary designs of the fridge holder/powerstation thingamajig!

  Details of this are still being ironed out, so please check back!

As of 12/23/05 i have the 2awg cable run to the back of the rig and connected to the inverter and i have a hardwired 12V cig receptacle to run the fridge and all is working great.  I still need to install fuses and fans into the box before its finalised!