Adding second battery box
I'm planning to add a second battery box in the usual position at the front of our 1988 Excella. I've got a used box and door from the local wrecker's yard, and would appreciate advice from you all on a few points:-
1. It appears that the plastic box is sandwiched between the aluminum skin and the door surround using self-tapping screws. The flange on the plastic box is not wide enough to be pierced by the screws, other than by semi-circular bites out of the plastic. This means that the hole cut in the skin will need to be very accurate, so as to force the plastic box to fit without leaks. It would help to glue the box to the back of the door frame before fitting, but that looks tricky. I just have to cut the hole very accurately, so what tool would you suggest? I have aircraft style snips, but these would distort the metal. I have an electric jig saw. I have a 4 inch electric disc grinder. How about a Dremel?
2. To seal between the box and the skin, would you use Vulkem, or some of the thick sticky tape used for installing windows?
3. I see the existing live red wire runs from the battery to the Univolt via what appears to be an isolated thermal breaker or fuse attached to the inner skin of the trailer. I presume I should add a similar device to the new live wire from the second battery, rather than share this one device by connecting both live wires to it. What is this device, what is it's rating, and is there a particular source for these?
4. I am going to replace the Univolt with an Intellipower plus Charge Wizard. I presume this has no effect on these plans. Are there any other points I should consider before plunging some sharp tool into that vulnerable aluminum?
Many thanks, in advance. Nick.
Nick Crowhurst, Excella 25 1988, Dodge Ram 2500 Cummins Diesel. England in summer, USA in winter.
"The price of freedom is eternal maintenance."