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3rd Gen Dual Battery Setup

JonathanExp

Elite Explorer
Joined
August 26, 2018
Messages
36
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23
City, State
USA living in AUS
Year, Model & Trim Level
2002 explorer limited
here are my pics and my write up for a 3rd gen dual battery setup.

i had the local metal fab shop weld it together based on my design. the tray accommodates my 850 cca battery (7.5"w x 12"l x 7.5"h) and my 82 amp hour deep cycle battery (7"w x 10"l x 9"h). i use the second battery to power my rear 12v power panel (3rd Gen Rear 12v/120v Power Panel) mostly for my fridge. this setup requires moving the main fuse/relay box back alongside the brake booster to make room for the batteries. i also needed to slightly move around (flatten out) the wires running under the battery(s), extend one of the main positive wires coming out of the fuse/relay box to the main battery, and install a dual battery isolator. getting two batteries in there is tight so expect to spend some time to make sure you are not hitting the front a/c line, the brake booster, or the hood (keep that + post covered!). i also wanted to have my fuses right at the post so that took a while to find the right solution (used an Iveco battery terminal) for my starter, alternator, lights, stereo, isolator, etc.

finally, i installed a thin sheet of rubber between the bolt points on the tray and frame and installed rubber hose around the threaded battery tie downs.

if i had to do it again, i would ask the fab shop to make the bolt mounts at the bottom of the tray larger to create more surface area to spread out the weight. i have done some off roading since then and there has been no bending of the metal but a larger bolt area would not hurt.

just remember to cover the + positive battery leads with something when test fitting your design. hitting the hood with a + lead would be a disaster.

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test fitting the fuse/relay bracket to angle it just right. the most forward facing bolt uses a factory threaded bolt hole. i cut a slice in the metal for the middle part of the bracket and used a self tapping screw for the back bolt.

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just enough lean to clear the hood strut.

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laying these wires flat so the tray can be as low as possible.

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test fit at the fab shop. used locking bolts on the bottom of the 3/8" threaded rod. i also drilled holes on the tray sides for zip ties.

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back from the powder coaters.

20200601_155045.jpg


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with isolator mounted on the firewall.
 






Nice set up congrats
 






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