Bongo Fury

Having been inspired by, among others, CorBlimey, and with a supply of parts from Martin (willinton, on ebay), I thought I'd post some pictures of my installation. Nothing new or fresh, just to show that it is quite a straightforward process. Mechanically I'll tackle pretty much anything, but electrickery only serves to confuse - but if I can do it, anyone can...

Here's the under bonnet installation, showing a moulded battery tray, a Bosch 110Ah battery (£62 from Costco), and one of Martins Relay Kits (before he started using the intelligent relay.



I have used 27A cable from both batteries to the relay, with 25A fuses on each connection. You can see a 60A cable that goes through the large grommet in the bulkhead behind the expansion tank.

From the inside, you can see a strip fuse holder connecting to the incoming 60A cable from the battery, with a 'distribution' of 4 27A cables on the other side of the strip fuse leading to an 8-way fusebox. The strip fuse is rated 30A continuous, 60A blow. Both fuse holders are mounted on a delrin plate, clipped in place on the steel tube that crosses the dashboard.



I chose 60A, as the circuits I'm linking are 10A, 15A, 15A & 15A (fuses 1, 6, 7 & 8 on the fuse box diagram) I realise that they won't all be on at the same time, but I'd rather have 'too much' cable capacity than not enough...

Finally, on the other side of the fusebox, 4 tails lead behind the dash to the small fusebox to the right of the steering column, as per CorBlimeys method.



Happy to say that everything worked first time, I have all that I currently need running off the leisure battery, and the charging system works; I can hear the clicking of the relay...

For those that have indirectly helped and inspired; thank you. For those that are considering doing it, what's stopping you ?

looks nice and neat

almost makes me tempted to rip mine out and redo it but since it works i will wait till it brakes

nice to see the photo's

nice one paul, i am just in the process of ordering all the parts for this job, i hope mine goes as smoothly as yours, i will let you know, ,LEE

Hey Paul,
Real nice install you have there. Your post & Corblimey's Instructables has prompted me to get the long awatied leisure battery installed.

One question where did you source the 30/60 Amp Strip fuse holder I can't seem to locate anything like this. Looks great as it seems you can squeeze those output cables into it.

Cheers

Stu

Stu

This site is useful:

http://www.autoelectricsupplies.co.uk/product/291

Although I got the Strip Fuse holder from e-bay:

http://cgi.ebay.co.uk/STRIP-LINK-FUSE-H ... dZViewItem

Nice install paul, i only have a four way fuse box, my interior lights, and radio are patched through to the L/B. Once daveblueozzie ...i mean I have got round to patching the blinds to the L/B then i'll be on my limit for available spare fuses,thats a good bit of foresight to use an 8 way jobby....

Thanks Paul,

I ended up ordering from http://www.autoelectricsupplies.co.uk/product/291 as I needed a host of other bits

Last night I fitted my battery tray. Being the tight wad that I am I decided to make my own battery tray, which was welded together out of bits of 1" angle I had lying around the tray is all fitted & looks strong enough to hold a tank in Will post back here with some pics to show the final install, but I suspect it will look very much like yours

Cheers

Stu

looks great
i'd be interested to see the tray you made up out of angle iron ? im thinking of doing the same - any pics ?

cheers Dave

Hi Dave,
I had fitted the battery in the self built tray when you posted & dont really want to take the battery out at the moment, but theres a poor quality pic with the battery in below. It was pretty simple stuff really. A rectangle frame with a couple of upright flat brackets welded to the back & right sides, then a long down piece like an upside down "T"(you may just be able to make it out) the "T" has holes in it to attach to the car as do the upright brackets. Took about 45mins to make & cost nowt. Well a bit of welding wire & gas

Stu

Paul,
I have started to assemble the fuse panel as you have on a board to secure behind the glove box, in fact Im almost finished.

One question how did you connect the 4x27Amp cables & the 60Amp wire to the inline fuse. Did you use yellow lucar eyelet crimp connectors to secure to the fuse bolts or did you just put the wire under the nuts. There seems to be a heck of a lot of copper to squeeze under the nuts of the fuse & I cant think that the connection would be that great.

Cheers

Stu

cheers for that looks good .. i'll be measuring up and doing a simillar thing i rekon, goto be saving the cash by welding one up myself

sdemmery wrote:Paul,
I have started to assemble the fuse panel as you have on a board to secure behind the glove box, in fact Im almost finished.

One question how did you connect the 4x27Amp cables & the 60Amp wire to the inline fuse. Did you use yellow lucar eyelet crimp connectors to secure to the fuse bolts or did you just put the wire under the nuts. There seems to be a heck of a lot of copper to squeeze under the nuts of the fuse & I cant think that the connection would be that great.

Cheers

Stu

I did use the large yellow crimp terminals, but removed the yellow plastic sleeve, and eased open the 'hole' to accept the 60A cable. Crimped then used heatshrink... For the 27A cables, I used 2 smaller crimp terminals, 2 cables per terminal, bolted back to back in the strip fuse box.

Thanks Paul,

I knew there would be an obvious solution, right Im off to the the auto shop to get more bits

I have to say my bongo is looking a little worse for wear at the moment, nearly all the interior panels are off as Im doing other work at the same time. My wife said what the hell is going on in here when she got in the other day, I told her when I find out I will tell her, she didnt look impressed

Stu

I was very pleased to see the security of your wiring on your pictures. The use of stick pads and zip ties can not be underestimated. To anyone installing any wiring in their cars, make sure the wires are supported and do not rub on anything especially anything metal at earth of the car potential as it is so easy to cause a fire in cars.try to route wires behind or around potential snagging areas and ensure fusing and wire gauge are adequate as well and you will be safe. Ensure that the correct size crimps are used for the gauge of wire, as they can pull out easily and cause short circuits. One small error could cost lives. I have seen so many bodged wiring jobs that have by luck not caused a problem. a car battery has a lot of oomph and needs respect.

richie

richie wrote:I was very pleased to see the security of your wiring on your pictures. The use of stick pads and zip ties can not be underestimated.

Just for a brief moment, I thought you were being sarcastic...






You weren't, were you ?