Wiring for deep cycle batteries in trailer

[Velo son]

We came in need of deep cycle batteries in the Echo 3 Offroader trailer because most of the remote campsites do not have electricity.

This modification involved routing a + and - cable from the Hilux's battery to the tailgate, ending with a plug. The wiring of the trailer started with a plug and was routed in the channel of it's chassis with the harness for the lights. The cables will enter the battery box with a rubber grommet.

Let's start off at the Hilux's (2.7 IFA 4x4) battery:
From the battery the cables are routed backwards towards the firewall and the positive gets a fusible link (near the fuel filter) with a 100A fuse. From there both cables run along the firewall (behind brake fluid lines) towards the brake booster. There it turns downwards to the chassis beam, avoiding the exhaust by passing behind a heat shield. From there it runs along a torsion bar and meets with the harness. As it runs along the harness it can be seen inside the wheel arch of the right back wheel. From there it exits the body through the hole on the top right next to the number plate where it ends with a plug which is fitted to a aluminium bracket which is fastened to the Hilux with 2 skrews.

Now for the trailer (Echo 4x4, Echo 3, Offroader):
The cables enter the trailer through the rectangular hole underneath the hitch, from there it runs inside the channel of the chassis, passing the axle and suspension, towards the battery box. The cables will enter the battery box through a rubber grommet.

The battery has a power supply which can charge it from 240V. Thus, the battery can be charged whilst driving (connected to the Hilux) or when 240V electricity is available.

The lights in and around the trailer(12V) are LED strip lights which can be cut to whatever length you need.

A shorter lead will be made from the same cables and plugs to provide the fridge with power inside the canopy when we are not traveling with the trailer. When we are traveling with the trailer the fridge would be inside the trailer.

NOTE: This project is not finished yet. Here are some pictures of the progress until now, I will post more pictures when the project is done.

Photos:
Fusible link with 100A fuse

Against firewall, towards brake booster

Downwards towards chassis

Along torsion bar, protected by heat shield.

Along harness, seen from hind wheel arch.

Along hind lights harness

Entering the trailer

Inside the channel

Expect more photos

[Donkey]

Hi SW

Whatever you do make sure your connections are either crimped or soldered (if not already) with no loose connections. Also I suggest you also put your wiring in that black flexible ribbing/tubing to avoid any chance of the insulation rubbing open against the body and causing shot circuits.

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[WESKUSKLONG]

Hi SW

Whatever you do make sure your connections are either crimped or soldered (if not already) with no loose connections. Also I suggest you also put your wiring in that black flexible ribbing/tubing to avoid any chance of the insulation rubbing open against the body and causing shot circuits.

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+1

[Velo son]

Thanks Tumelo+Rudi. The crimping of the lugs will be done in a day or 2

[FJCruiser-ZN]

It's better to go with a DC/DC charger, you can run much thinner cables to the back.

Unprotected heavy duty wiring isn't a good idea, many 4x4's have burnt out because of an electric short.

The 100a fuse near the battery is a must, however if the fuse blows because of a fault, you'll end up with flat batteries.

T

[Velo son]

We are almost done, a few mishaps retarded the progress...
We realised that the battery is too high for the battery box --- so we placed another battery box inside the trailer and will be using the original one for storage space.
We installed a relay after we were informed that the power supply would use some of the batteries power when not supplying power.

Progress up to present:

Cables entering trailer through rubber grommets

Fused positive cable with shrinked lugs covered in heat-shrink sleeving.

Anderson plug at rear of Hilux. Fixed to an aluminium bar

Battery inside box tied to the side of the trailer's inside

Battery with its connections

Power supply and relay fixed to inside of trailer.

Strip lights fixed on the ouside of the trailer. It has a LED every 8cm and provides more than enough light.

All that is left to do is to add some more connections for chargers and the fridge ect.
We are going camping this weekend, to test the system. I will take some more photos of the Hilux and trailer in action and upload them.

[Mars]

Looking good! They call the stuff ribbed sleeving and it is not expensive. You can get it at most sound installation shops.

[Big D]

Midas and Autozone stock it aswell, and cheap