Trojan T105 install, Blue Sea switch

[Kalashnikov]

Completed my first major AS mod today! Installed a couple T105 batteries along with a Blue Sea switch.


I was stumped when I realized I couldn't use the automotive type connectors with my Trojans. Scoured the web for ideas and finally went to my local auto parts store and bought two types of connectors: soldered 3/8 rings and bolt-on 3/8 rings. Ended using the soldered version since the others would not have fit inside the Blue Sea.


For the switch I went to Home Depot and found a 4x4x2" plastic junction box. I decided to use the existing 1.5" opening in the AS battery box for passing my cables. This worked ok but the junction box ended up being rather congested. My wife had to pull the cables from one side while I bent and pushed on the face of the box, it was very tight. I'd go with a slightly bigger box next time (blood was shed )


The T105 batteries fit perfectly within the stock AS battery box, this is on a 2019 model and the box is 12" high. At first I modified the factory plastic tray and intended to place the batteries in the original location but one of the bolts from my switch box interfered slightly. I didn't want to risk creating a hole in the battery over time so I threw away the tray and moved the batteries back. I stuck a piece of 2x4 in there to make sure they don't slide around (ie. 3.5 inches of gap at the back of the box.)


Thanks to wulfraat for his excellent wiring diagram! I modified as follows:
- 6v series instead of 12v parallel
- Inverter on "1", camper on "2". This way I never actually use the "1" position, it's either OFF, camper only [2] or inverter & camper [1+2] as I twist the knob clockwise (Blue sea 4-position switch.)


Bolt cutters to remove old connectors






Soldered connector. Smeared some 'Goop' on exposed piece of copper wire after the soldering.




Empty box




Junction box and hardware




Back of switch, installed in junction box face




Junction box installed, waiting for switch & face




Switch in place! (By far the hardest part due to stiff cables)




Completed installation

[pcskier]

Originally Posted by Kalashnikov

Completed my first major AS mod today! Installed a couple T105 batteries along with a Blue Sea switch.
]

Nicely done. Get some paint on that box and you’ll be finished [emoji16]

I did the exact same thing a couple years ago, same switch and all and a homemade box. Moved the switch inside trailer last summer when I did my solar upgrade. It’s nice to know the inverter is truly ‘off’ and really nice to take the batteries offline so easily between trips.

Your gonna love those batteries. Kick the tar out of the Interstates.

[Peykojoe]

Great looking job. Do you have a link to the wulfraat wiring diagram? I want to do the exact same thing.

[AirMiles]

Duracell EGC2 6V Golf Cart Batteries from Sam's Club, Batteries Plus, and Costco have both sets of battery connections. These are quality 6V golf cart batteries manufactured by Deka East Penn. I'd say Trojan's are the highest quality 6V battery, but the Duracell EGC2 aren't far behind. And I like that they have both terminals so you don't need to mess with changing the connections. Just add a heavy gauge crossover wire between one positive and one negative post to get 12V. Picture of my Duracell EGC2's all wired up in the battery box: http://www.airforums.com/forums/f42/...ml#post2079369

[GMFL]

Lookin good

[Kalashnikov]

Originally Posted by Peykojoe

Great looking job. Do you have a link to the wulfraat wiring diagram? I want to do the exact same thing.

I didn't do the _exact_ thing has wulfraat. He shows two options:
1) 12v parallel batteries, single pole switch
2) 12v parallel batteries, 4 position switch



My changes:
- Two 6v batteries, meaning one [+] to [-] wire between them
- Used the 4 position blue sea switch but connected the Inverter to "1" and the trailer to "2"


Thus I use the switch like this:
- Keep in OFF when not using the trailer
- Turn clockwise to "2" when using the trailer (but no inverter)
- Turn clockwise to "1+2" when using trailer _and_ inverter
- Seldom use "1" (inverter only)


Works best for me since I'm right handed and don't wish to flip flop the switch back and forth. The sequence is most natural this way IMO.


The switch:





2-pole diagram from wulfraat





4-position switch diagram from wulfraat

[Kalashnikov]

Today I bought this 1.5" conduit box, I'm planning on installing the Victron 712 battery monitor shunt in the battery compartment as well.


Per victron the shunt is roughly 2"x2"x5", should fit perfectly in this box. I have about 3.5"x10"x10" space available within my battery box after the Trojan install. I'll find a separate box for the victron itself, it will be on the outside of the battery box.

[Kalashnikov]

Also, sold the OEM batteries for $125 for the pair.

[Peykojoe]

Kalashnikov :

Thanks for the reply. That is a great diagram and will be perfect to help me put mine together.