Builds OL'BETSY ZX: 1991 HZJ77 (2 Viewers)

[JDM Journeys]

Sometimes 24 volts messes with my head. But today was a day to confirm that what I had mapped out in that messed up head would work.

My goal was to power my CB (yes, I know, but there are guys in my group that still run them, and its a tiny unit) and the 12v socket in the dash via my rear battery. This would be easy except I wanted it switched, so it wouldn't stay on when the key was out. So here's what I did:

1. Disconnected the cigarette lighter socket. Use the switched power instead to open a 24 volt relay (pin 30)
2. Hooked the CB and (now powerless) socket to pin 87 on the relay
3. Sent a fused connection on my rear 12v battery to pin 30.
4. Grounded the relay at 86.

I figured a 24volt relay would be appropriate, since the 24v power source was what I was using to open and close. The rest is simply passed through. At least that was my theory.

The result, with key on:

My tiny "President Bill" CB (occupying what used to be the ashtray) powers up, and my heretofore 24 volt socket now reflects the state of charge in the rear battery, plus the cabin temperature, plus a USB outlet. (Yes, my rear battery is getting low - its been on its own for a long time. Soon it will be getting some love from a 24->12v converter).

So I'd call this a win. Except I better not take up smoking.

 

[JDM Journeys]

Victron Orion 24 to 12v converter/charger

Goal here is to keep my 12v AGM battery topped up, while running a small Dometic fridge and a few small accessories. No induction cooking here. Solar will eventually be added to supplement.

More electrical progress yesterday. Began wiring in my new Victron 24->12v converter. After much deliberation and consulting wiring charts, I settled on the following...

Converter is 25 amps, with max of 35. So I started at the battery (high side obviously) with a 30 amp resettable circuit breaker. This feeds a 10 awg wire that goes through the firewall, under the door sill plastics, and back to my converter, next to my third battery, between the drawers in the back of my truck.

The wire is only about 8 feet long, so feeding 24v through it should be plenty enough to reduce voltage drop/heat, but not so thick that it was difficult to run/hide.

I still need to run a 24v switched power source to turn the unit on with ignition. The lead running to the power lumbar switch in the driver's seat is perfectly positioned, and only comes alive when the truck is running, so in aux position the converter won't run the battery down. Might not hurt to put a manual switch in too, in case I don't want the converter running at all?

Then it's simply a matter of the short run from converter to battery, and a ground connection. I'll also put a fuse on the aux battery side too, just for redundancy.

If anyone sees any issues here, feel free to shoot my system full of holes. I've spent far too much time thinking this through, and it's high time to put it together. Pics to follow.

(tagging @svsisu who was asking questions via pm)

 

[Felde]

Sounds good
In a dual battery setup like this, a fuse near each battery is mandatory!
In case of a short circuit, with only one fuse, even if that blows, the firework would just go on, being fed from the other battery. Fuse dimension must be identical.
I'm curious, what's the exact type of your Victron charger, please?
Cheers Ralf

 

[JDM Journeys]

Yeah, I'm not a great welder at the best of time, so I'd rather avoid any impromptu sessions. LOL.

Here's my unit:
Volts.ca link to Victron Orion 24/12-25A dc to dc

I do wish it had a more heavy duty terminal style lug hookup, but at least it's compact, and for 10 gauge wire is perfectly adequate. Let's call this a light duty setup, and it will be viewed and used as such. I don't really want to pull any more away from the stock charging system than is absolutely necessary. Once I pony up for some flexible solar panels, this thing should be a much less prominent member of the system.

And yes, same size fuse on house battery side. This is a 25 amp (continuous) unit, but 35 amp max. I used a 30 amp circuit breaker and will fuse the other end the same way, figuring if I'm approaching max output then I'm pushing it too hard anyways. My calculations indicate that running the fridge on the 12v battery with the 24 volt system charging it (even before solar is added) will keep the battery charged indefinitely while the truck is running.

Disclaimer: no professional advice implied here. As if you needed to read that!

 

[JDM Journeys]

Stage one of my AUX electrical system is finally in place. I had it done but wasn't happy with it, so today I rejigged my positioning of the 24>12 converter, and it's much better.

Here's some quick pics...

1. The switch panel at the back... This is sitting between the two drawers, and the top lifts up to access the electrical goodies (ignore the multi socket 12v plug in the pocket - just stored there). This is the switch panel in its "off" state, such as when the truck is parked for a while.

I hooked this up so that the right-most switch turns on the voltmeter, usb socket, and 12v socket, as well as the resting LEDs in the switches.

Like this:

I still need to do the carpet underneath, but you can see the access panel for the lower storage compartment, with a hole to lift out the hatch.

Time to look under the cover.

Okay, admittedly there are few circuits yet, but lots of room for expansion.

LHS has the 24->12v converter. On the deck is the small 24v fuse panel. RHS hosts a larger 12v fuse panel.

Any wire coming in that is 24v is labelled such. Just in case. Probably didn't need the 24v fuse panel, but it doesn't hurt. The 12v panel is a 12 gang, and allows for grounding as well.

I still have some more circuits to add, but for now I'm happy with the setup. It'll be nice to be able to finally charge up the AGM Exide again, without having to put it on the charger when I get home.

 

[JDM Journeys]

Started her up yesterday for the first time in 3 weeks. No dramas, minimal smoke. Excellent! It seems I've finally licked the air/fuel issues.

 

[Gun Runner 5]

Started her up yesterday for the first time in 3 weeks. No dramas, minimal smoke. Excellent! It seems I've finally licked the air/fuel issues.

3 weeks?
You are lucky your Cruiser can‘t call one of those 1-800- NEGLECT numbers.

 

[JDM Journeys]

Well I was driving the two other cruisers. And the weather was sloppy, so actually it was out of love that she didn't get out in the sand and salt.

 

[Jordan345]

Looks great, nice progress. I havent checked in for a while but there are some neat ideas that i hadnt thought of. Really keen on the charge read out in the cig lighter for the rear battery.

As for alternates to charging the 3rd battery i had used the red arc unit from oz which keeps it constantly charged from the alternator and converts to 12v.

 

[JDM Journeys]

Some small progress...

So first off, the Victron DC>DC is doing the job, and a small turn of the pot allows me to vary the charge rate, so my AGM 3rd batt is now getting a nice warm 14.6 volts once the truck is running.

In the same electrical vicinity, I made a cheap/dirty 12v power access port today. I'm almost embarrassed to show it here, given the other options I've seen, but mine cost under 15 dollars, so I guess it has something going for it? I pulled the exterior vent louvre/grill thingy, and (after confirming that they are still avail new) I did some trimming with my dremel to the point where I could route an SAE port in through the vent. Used a hose clamp on the back side to keep it secure, and routed the wires under the trim and down inside and out at the bottom by the carpet, where it can snake under the drawer and join the party at the fuse box. I'll probably switch this one too, so I can turn the awning lights or rooftop tent power on and off easily. But here's how it looks. Not super pretty, but functional, and the way the wire is routed, the vent should remain 100% factory functional...

Yes truck is dirty dirty...

 

[AirheadNut]

That's a great idea. An Anderson Powerpole outlet would be another good option there depending on one's preferred connector.

 

[JDM Journeys]

That's a great idea. An Anderson Powerpole outlet would be another good option there depending on one's preferred connector.

For now I only need this to power my awning lights and a usb up to the RTT, so very little draw overall. But I'll see how it goes. I do like how little the intrusion is with an SAE plug.

 

[JDM Journeys]

Two steps forward, two steps back this week. I brought my truck to work, where a parent of some of my students was going to vacuum down and pressurize my A/C system to check it for leaks, and hopefully get it functional again. I've had the belt and pulley off for a bit since A/C was not working, and hastily threw it back in place the night before I drove it. Yes, hastily.

Thought I detected a faint burning rubber smell just out of the garage, but just a hint and I passed it off as nothing. Yeah, no. Got to work, did a quick check of the system to ensure all was well before my guy spent his valuable time on it for me. And realized that I had incorrectly reinstated the pulley with the bushing on the wrong side of the bracket. This bent the adjuster bolt, kept the pulley from turning, and burned up the belt. Great job!

I quickly called him and rescheduled for later in the spring. To save face I simply said that the pulley was seized. But we know the reason why... Arrrg. New bolt, belt, and a few other things now on the way (filters, spare fan belt). I was hoping to hold off on another order in case the A/C charge revealed other components needing replacement, but oh well. Stupid is as stupid does.

 

[JDM Journeys]

In other news, I finally have a big trip planned for this summer. We are going to Overland Expo PNW! Taking as many backroads (Canada) and BDR's (stateside) as we can, and only hitting pavement when we have to. So this gives me motivation to get working on some things I've been putting off. A/C is one of them.

Here's a story to go with the start of the trip planning...

Destinations: Are They the End or the Beginning? - The Gearhead Project

Because a new JDM Journey is long overdue and having a destination in mind gets it started.

www.thegearheadproject.com

 

[Guyute]

In other news, I finally have a big trip planned for this summer. We are going to Overland Expo PNW! Taking as many backroads (Canada) and BDR's (stateside) as we can, and only hitting pavement when we have to. So this gives me motivation to get working on some things I've been putting off. A/C is one of them.

Here's a story to go with the start of the trip planning...

Destinations: Are They the End or the Beginning? - The Gearhead Project

Because a new JDM Journey is long overdue and having a destination in mind gets it started.

www.thegearheadproject.com

See yah there!

 

[Rigster]

Bummer Phil, I hate it when I pebcak like that... I feel for ya! Been there, done that. Nothing to do but take the lumps to the pocketbook and learn from it! You are still further ahead doing the work yourself even when there are some learning expenses like this. Consider it tuition!

Sounds like an adventure heading to the expedition expo! Though it sounds like getting there is the highlight, with the potential to see some neat innovations midway through the trip at the expo. Are you planning differing routes down and back? Sounds like some great fun!! Excited for you!

 

[JDM Journeys]

So today I took the truck to work for the fifth day in a row, and realized I had just rolled up 10k kms since I bought it. Since I really only started driving it last spring, I'm pretty happy to have put so many ks on. This is not a daily, and is one of four vehicles we have.

I did get back to some mods this week, and finally installed my water pump. Here's a sneak peek...

Some finishing up to do before I go camping this weekend.

 

[JDM Journeys]

New windshield is IN!! What a giant difference! Hard to capture how bad the old one was, but I haven't seen too many that were cracked, pitted, and chipped like this, yet still driving down the road.

It was a bit eerie when I went to take it to work yesterday. Felt like there was no glass.
Kind of like this:

New seal was uber tight, and my mobile install guy had to get his other pro friend to come and help. Parts of it I couldn't watch... a lot of slapping going on. Yikes!
But it's in. What a relief.

 

[FJ73Texas]

Did they seal it afterwards?

 

[JDM Journeys]

Did they seal it afterwards?

Nope. Going to do it myself after it sees some heat. The seal was very stiff and it's still settling in a little, AND it hasn't really warmed up here yet. But I will according to the instructions in the FSM.