FZJ80 Cable upgrade (5 Viewers)

[Otamiway]

After reading a couple threads on cable upgrades, I decided to contact Mark (FourRunner) for a set on his cables

https://forum.ih8mud.com/merchandise-storefront/479096-fzj80-heavy-duty-battery-cable-sets.html

I went one step further and had Mark make me a custom 2 piece 1/0 Alternator cable. Thanks to Poppy Walnut's thread for the idea. I added a 200 amp fuse in anticipation of doing the Photoman 150amp upgrade soon
https://forum.ih8mud.com/80-series-tech/525391-battery-rewire-finished-results.html

This weekend I started the install.. I was only to get to the Fender ground, the alternator cable, Block ground and Starter cable.

I am very impressed with the quality on the cables. Thanks Mark

 

[Otamiway]

More pics

The block ground could have been about 2 inches longer. The original ground had a right angle ring end terminal. I will take a better picture of it. I also had to ditch the grey plastic cover on the starter. As you can see the new Red booth fit like a glove.

 

[Otamiway]

Battery Connection

I am going to check the voltage later in the week and report.

 

[Fourrunner]

Thanks for the kind words...impressive work and nice install.

 

[Otamiway]

Thanks for the kind words...impressive work and nice install.

Thanks Mark..

 

[Tapage]

are really better those military batt terminals ?

 

[Otamiway]

are really better those military batt terminals ?

IMHO yes...it allows you to securely attach multiple connections as seen in my pics above.

 

[Fourrunner]

I know exactly what you mean on that right angle lug. I recently looked at an FZJ80 with my kit installed and saw the issue. Figured I needed to fix that issue and was able to track down some right angled lugs This right angle lug will be standard for the FZJ80 kits from now on. Sorry yours doesn't have it.

The mil spec battery terminals seem to clamp down to the posts a lot better and as Stu mentioned, it gives you the ability to attach additional wires.

 

[Ebag333]

These are nice. Gonna be on my list of things to get.

Milspec terminals are nice, but I also like the marine style. I actually think I prefer them a bit over the milspec.

ANCOR MARINE Terminal at West Marine

 

[Fourrunner]

Ebag333,

I can get those for you as well. The set I can get aren't tin coated, but epoxy coated red and black (positive and negative). Please contact me when you are ready to move forward and we can get you set up.

 

[Ebag333]

I love epoxy coating. Lasts forever and completely resistant to anything (like battery out gassing). Not so much an issue with an AGM battery, but still nice to have.

 

[Otamiway]

These are nice. Gonna be on my list of things to get.

Milspec terminals are nice, but I also like the marine style. I actually think I prefer them a bit over the milspec.

ANCOR MARINE Terminal at West Marine

Ebag333, those are very nice. I went with the Milspec because it was easier for me to attach multiple leads on both sides.

 

[Ebag333]

Ebag333, those are very nice. I went with the Milspec because it was easier for me to attach multiple leads on both sides.

I have the PM-1, so have an accessory terminal built in. So having both sides wasn't necessary for me (or most people, I suspect). You can fit a lot on those posts.

Now one of the down sides is that they are pretty fat, so the ones I have don't fit the fusible links. The accessory terminal (on the battery) is nearly the perfect size, however, so a tiny bit of grinding and they fit nice and snug. That leaves the marine lugs for all my accessories. (Backwards, but it works!)

It's actually a bit odd to me that the holes on the links are so small OEM. Guess it's a metric thing.

 

[Otamiway]

Ebag333, sound like a great setup..

 

[Itchy Sides]

Whoa...nice terminals!

I upgraded all the cables, etc., on one of our VW's years ago. Wasn't too difficult, made a nice difference, and has held up well for over a decade

 

[e9999]

OP: you are replacing the fusible link with a 200A fuse is that it? Fast, slow?

May be nice to have a main switch in line too, to avoid starter fires, discourage theft etc.

 

[Otamiway]

OP: you are replacing the fusible link with a 200A fuse is that it? Fast, slow?

May be nice to have a main switch in line too, to avoid starter fires, discourage theft etc.

Original fusible links are still in place.

 

[flow]

I have installed Photoman's bracket and a 150 amp alternator and I am looking at this kit to help me take full advantage of the upgraded alternator.

What, in addition to this kit, should I upgrade? Heavier fusible links or a 150 amp in-line fuse?

FYI, I am installing an aftermarket sub and eventually a winch.

Sorry for the thread-jack

 

[Otamiway]

Flow: I have a set of Photoman brakects waiting to be installed. The basic kit and the custom Alternator line Mark did for me will definately allow me to get the full benefit of the 150amp. I added a 200amp fuse from west marine to handle to new load.

This would be perfect was to prep your rig for the additions you are going to make

Do you have a dual battery kit? Share more info about your rig.

HTH.. Stu

 

[CycloSteve]

Mark also built the main cables and second battery cables for my rig. Excellent crimps without a doubt!

With the Negative cable to the block, I asked a friend who used to have a machine/welding shop if he had any material which I could use to get a better angle at the block. He said that he had some small blocks which were already drilled at 90 degree angles. Thus I only had to open one of the holes up slightly to have the bolt fit to the block, and also tap the second hole for the cable.

Essentially now the cables bolt at a 90 degree angle to the block (both the main and second battery). No stress on the cables.

Here is what one of these looks like.



Steve

and with the cable attached.