I got my dual battery system on my 1988 FJ62 finished up last week (mostly), and finally got the pics off of the work camera to do the write up, as promised. I chose to do an isolator system, and incorporated a switch between my aux. and main battery for jump starting purposes. I know many have probably done this, and the plan is that if I ever kill my main battery, I can flip the switch to "on", and jump start myself. I ran into an issue with the isolator I had selected, and the first time I installed it and started it up, I was getting no charge. I used a standard 3 post isolator, and the internally regulated alternator of the 62 and the 3FE 80's would not excite without a 12v feed. If I had the main battery hooked up directly to the alternator, then it charged fine. I had to run it this way for a few days, with the main battery charging direct, and the aux charging off the isolator, until I figured out what isolator I needed. I talked to Sure Power (www.surepower.com) here in town, and they told which one to use, either the Sure Power their 9523A or 12023A. They are the same isolator, except the 9523A is rated for 95 amps, and the 12023A is rated for 120 amps. I went with the 12023A so that I can upgrade to a HO alternator in the future without having to replace my alternator again. It's a 4 post isolator, with the 4th post being the excite post. The way it works with the internally regulated Denso alt is by tapping into the ignition feed wire on the wiring harness going into the back of the alt, and running that to the "E" post. Then wire your alternator and batteries up.
As far as installing the tray and the other what nots, that was fairly easy. I picked up a used tray and hold down bar here on mud from shmukster, who was parting out another FJ62. I stripped them down, as the powder coat was starting to lift, primed them with a two part epoxy primer, and painted them with Plasti-Dip. The tray bolts right in, as the fender well and core support already have the bolt holes for it, and the tray's are not side specific. To make room for the tray I just removed the air pump muffler, and attached a piece of hose the hangs down below the tray. This was upon the suggestion of other mud members. I ended up fabbing my own suppport bracket, and incorporated my overflow bottle bracket into that, rather than buying the part from a 24V diesel rig. I just used 1" wide and 1/8" flat stock, made the proper bends, cuts, and turns, and tack welded a bolt into the bottom hole to act as a retained stud like the OE bracket. Then welded a small strip vertically to attach my bottle bracket too. I had some good pics of the bracket as it was being done and before it was in, but I took them with the work camera, and the boss deleted them not knowing I hadn't uploaded them yet.
But here is the pics.
As far as installing the tray and the other what nots, that was fairly easy. I picked up a used tray and hold down bar here on mud from shmukster, who was parting out another FJ62. I stripped them down, as the powder coat was starting to lift, primed them with a two part epoxy primer, and painted them with Plasti-Dip. The tray bolts right in, as the fender well and core support already have the bolt holes for it, and the tray's are not side specific. To make room for the tray I just removed the air pump muffler, and attached a piece of hose the hangs down below the tray. This was upon the suggestion of other mud members. I ended up fabbing my own suppport bracket, and incorporated my overflow bottle bracket into that, rather than buying the part from a 24V diesel rig. I just used 1" wide and 1/8" flat stock, made the proper bends, cuts, and turns, and tack welded a bolt into the bottom hole to act as a retained stud like the OE bracket. Then welded a small strip vertically to attach my bottle bracket too. I had some good pics of the bracket as it was being done and before it was in, but I took them with the work camera, and the boss deleted them not knowing I hadn't uploaded them yet.
But here is the pics.
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