Kiwipetes 2nd battery install mod

[kiwipete]

Well I have finally gotten around to installing my second battery.
I had to remove the air filter and washer bottle to fit the new battery tray in place. Some minor modification was required for the base of the air filter to allow it to sit in its new place, the drawback being it is very tight getting the lid and filter off now.
The washer bottle was pushed as far back to the firewall as I could get it. moved the rear window pump to a new location on the bottle and modified the bottom bracket too. I still have to fab up a small top bracket to stabilize it yet.
The main power wire for the winch solenoid has yet to be connected. I am going to attach the solenoid mounting bracket to the side of the air filter box. The remote control receiver will sit in between the solenoid and washer bottle.
I also made a relay plate to hold about a dozen relays for various accessories as well as some spares for future projects.
The VSR (140A) is zip tied to the side of the battery until I decide where to mount it.

All cleared out.


New additional wiring looms added and battery tray in.


VSR


Secondary battery negative lead from a junked Terrano.


Modified air filter box and tray.

I like shiny objects.

There, all done, well almost all done.


Shock horror! Look what I found under the plastic "Airflow" snorkel when I removed it. This was fitted by a reputable 4X4 shop in Christchurch. Yes it was done about 5 years ago when I bought the truck, but I will be going back there to give them a piece of my mind and ask for some explanation!

This is the 2nd such so called expert/professional shop that I will not be dealing with in the future!
Once bitten twice shy.

I have a new snorkel in the making that will be going on as a replacement as I can no longer plumb up to the Airflow one with these modifications.

More photos to come later.

[sibainmud]

Nice pete. Looks like ya really got the shoe horn out
One day soon you're gunna run out of space under that bonnet.
Crap snorkle install. See you are going to put air direct through inner guard.
Mate you are a credit to us DIY'ers

If a builders house is shyt, a school teachers kids are dumb, and a mechanics car is a heap, what is a sparky's car like
Bet you could stretch out all that wire out to reach Dunners.

My second battery was going to be installed this week but has been deferred till after this weekends trip (3 days in 4x4 heaven again).

[kiwipete]

Cheers Simon.
All the winch power and solenoid wires will need shortening, but not until I have done the new front bars and re-located the winch.
Unfortunately the battery has to come out as there is some wobble in the mounting plate. In my haste to fit it all I left out a supporting bracket!
Yes the easiest way to re-plumb the snorkel was through the guard, it almost matches up perfectly to the air box but what a plick of a job cutting the hole. Have a very good friend customising the pre bent snorkel tube for me.

I am going to hound the previous installers for compensation for a plate to cover those horrible holes they put in there.

WE HAVE A PLAN......

PS, I have run out of room, looks like the horns have to go somewhere else now.

[kiwipete]

More work done today, because the battery took up the space where the air cleaner was plumbed into the guard for the "old" snorkel, I had to make way for a new one. Well only after discovering the old one could not be plumbed to directly through the guard.
The hole I cut in the inner guard turned out to be slightly out of alignment for the new snorkel, so the power file came in handy.


There is not too much in the way of a kink now for the flexi tube, after I repositioned the air filter yet again, (that's 3 times now).

I also fitted the brace that I omitted for the battery tray in my haste to fit things the other day.


Relay wiring was tided up after this shot too.


Trial fitting of new snorkel to see how it will sit.


For a pre-bent tube, I was a little puzzled as to why they have the inlet facing down as far as it is. You can see how the top is out of line now. We will cut the tube and twist it to the correct angle.


The snorkel.


Pyro fitted to exhaust outlet.


Almost done, well I still have to connect the main positive wire for the winch solenoid and secure the solenoid box yet.
The filter is a bugger to remove now, I have to undo the hose clip on the engine inlet to remove the filter lid now, yes i need a shoe horn!

[kiwipete]

Here are the progress pictures of the snorkel fitting from today.

Did I pay him to sleep on the job?


Hope it was measured up proper before you cut it Tex.


American style? Sorry, couldn't help it.


Cut n tacked.


Trial fit.


Moved air cleaner again to get a better alignment.


Takes a deep breath, more holes!


Studs on.


Nice lines Tex.




"A" pillar bracket on.


Much better now it's plumbed up.


There we go.


All I have to do now is paint it and Tex is going to make a nice cover to go where the green tape is.


Keep watching...................

[radar21]

looking good pete

[NJV6]

Nice job with the snorkel but I guess there is no trees in Canterbury.....

Shorten the periscope?

[Fakey]

Nice job with the snorkel but I guess there is no trees in Canterbury.....

Shorten the periscope?

Looks like its still lower than the lights an roof rack, Nice work

[kiwipete]

Etch primer undercoated the tube today. I have to source some good semi gloss paint to finish it now.
BTW, I coated the inner tube with "Blackguard"

[kiwipete]

looking good pete

Thanks, couldn't have done it without the help of my good friend Tex.

[kiwipete]

Nice job with the snorkel but I guess there is no trees in Canterbury.....

Shorten the periscope?

No need to do anything drastic like that, it's the same height the plastic one was.

[kiwipete]

Nice job with the snorkel but I guess there is no trees in Canterbury.....

Shorten the periscope?

Looks like its still lower than the lights an roof rack, Nice work

Yes it is lower than them, and I do not plan on going under trees that low.

[kiwipete]

The snorkel was painted tonight, I used saturn mat black spray paint, best option available to me at this time. I would have liked to get it powder coated, but funds are drying up. When scratched, it will be easy enough to mask it off and apply a couple of coats of spray paint again.
Got to keep it looking nice n shiny



Roughed the paintwork up for the black gasket silicone to stick better bonding the bling.





And............. the bling!!!!!!!
Big thumbs up to Tex for this one!




That's it for this mod now. Time to start another one, my winch bars

[lincooln]

wow, looks real good. looks better than my pool vac hose

[kiwipete]

wow, looks real good. looks better than my pool vac hose

lol, would be a little restrictive with the air flow, wouldn't it?
Thanks for the compliment.

[lincooln]

Its alright, its only on a Suzuki.