[vanasp]

Australian battery bracket

After many years of getting away without a dual battery system my wife and I did a 2-week trip to Zimbabwe in June this year and hence I had to fit a dual battery system. I like to know things are done properly and hence I surfed the internet to get ideas and do the installation myself.

I found and excellent link http://nicksphotoblog42.blogspot.com/p/ ... ajero.html
as well as https://www.4x4community.com/forum/show ... stcount=57
which both got me on the right track.

I started off making a cardboard template to check if my idea would work and the batteries would fit. You have to make sure you do not damage the aircon pipes or let the bracket rub against them. I then found a picture on the internet of a bracket you can buy in Australia which looked good. I cannot weld so I got a friend to weld up my bracket using 2mm steel to suit my needs.

Space available for second battery

Space available for second battery

Cardboard template

steel battery bracket

I brought the 10mm2 wiring from the back of the car, via the roof, down the front C pillar and through the firewall as recommended by Nick. I have had no rattling in the roof, which I thought might be a problem.

Brad Harris connectors in the back of the Pajero

We moved the crank battery (original) to the new position against the firewall and fitted the new 90AH second battery in the old position. The reason I used a 90AH is that the 105AH was too high and in my opinion the terminals were too close to the bonnet. The existing positive battery cables could reach the new battery position but I needed a new negative cable. This was easy to install but putting a lug under the existing negative mounting point situated just under the fuse box. The existing negative was taken to the new Aux battery.

both batteries installed. Note circuit breaker In-line to the feed to the back.

I bought my Cole Hersee solenoid from the agents in Centurion at less than half the price asked by most 4x4 shops. I mounted this on the front of my new bracket, it is a tight squeeze but fits with millimetres to spare. I fitted a DC circuit breaker in the positive lead to the back of the car which you can see between the battery and fuse box.

Cole Hersee solenoid

I fitted a control switch with a yellow LED on the LHS of steering column and manually control the operation of the charging solenoid. This is wired to a positive from the front cigarette lighter so that it is not possible to leave both batteries connected when the car is switched off. In time I will fit a timer circuit to control this function but did not have a problem remembering to do this manually.

Switch on dashboard

LED I mounted in the dash

I have not fitted any voltmeters but kept an eye on things using my Fluke multimeter during our travels and had no problems during our 14-day trip. In time I will probably add some digital voltmeters if I feel it is necessary.

[jkak]

gee what a hands on man!

I am a pen pusher. When can I bring my truck?

[vanasp]

Thanks for the compliment but sorry I will not take you up on the request to fit yours.Doing it for myself was bad enough but worth the effort to know it was done correctly. I see why the 4x4 fitment centers ask what they do, as it takes a lot of time and effort.

[jkak]

Since got one made up by my friend who now has a templet in case any one is interested

[vanasp]

Hi There, thanks for letting me know and the template should be useful for others. Did you also move your crank battery to the new position and second battery to the old position?

Enjoy having the comfort of a second battery.

Regards
Paul

[Mitsu Fan]

Thanks all for the input. Since I have a Pajero Sport, there simply is not enough room in the engine bay area without having to move the power steering pipes and the washer bottle filler. I have opted for removing the 6/7th fold down seat (got a tip under the Pajero Sport thread) and fitted it there, with the cables coming through the chassis dust cover in the left corner.
I am busy with the solenoid connection now, took the plunge and bought a National Luna assembly !

[sixmaniac]

After also spending hrs making up a bracket/tray for the 2nd battery, I discovered that Safari centre sells a nr of brackets specially made for different vehicles, incl the Pajero. They are about R300, incl even the screws and clamp. Makes more sense than all the time and effort to make up your own and then have it coated.

I also swopped the 2 batteries, and find that a 105amphr unit fits perfectly in front.

[vanasp]

Sixmaniac why did you only find this out now and tell me after I made my own bracket This will be a great help to others

[dvillier]

Hi, I have the bracket and the solenoid switch partt sorted out but I have a BIG problem with the routing of the cable to the back of my vehicle. I am interested in routing it via the roof but need more info please.

[vanasp]

Hi Dvilliers

I also routed my cables via the roof and it was very easy. I came from the engine bay via the big rubber boot where the main wiring loom goes through the firewall (See picture just before the cardboard cut out. Put some lubrication on the wire to help get it through and don't forget to pull in 2 x extra wires for operating the solenoid. Then to the passenger side behind the cubbyhole and up via the windscreen pillar into the roof. It is very easy to remove the roof lining just enough from the back door to feed the cables. Just be careful removing the plastic holding brackets as they can break fairly easily.

I started from the back and worked to the front. I used a fishtape to pull the wires from the back to the front of the car and then struggled a bit to get it down the front pillar but there is definitely more than enough space for the cabling. Just be patient and work carefully.

Hope this helps you.