starting battery

Franks comments:

"I put in the biggest GD battery that would fit in the diesel battery tray. Answer - the current battery is a Champion Silver UF-6. I long ago changed the battery terminals to side clamp style since the older high capacity batteries used the upper terminal are for larger capacity.

About 5 years ago the highest capacity batteries started coming out in theUF-6 style, which had top posts as well as side terminals. I leave the plastic caps on the top terminals just in case of contact with the engine cover.

The key killer of the batteries is engine compartment heat. As described in the archives, I fabricated a heat shield (used surplus multilayer ceramic composite but anything nonmetallic is fine). This built up like a box on the engine side of the battery, open to the bottom, but flush to the clamped engine cover. Used the equivalent of the poptop bubble seal - with bubble seal oriented along the top of the box. This lets cooling air flow in from the passenger side rear air vent and out the bottom rear while cooling the batteries.

Box connects at the mounting plate holding the coolant expansion tank and leaves 3 inches clearance to remove the battery, connect terminals etc. Box is readily removed if more involved R&R is needed. Mechanics at Wards think its stock. I had the pleasure of listening to one of their pseudomechanics hassle a Westy owner as to why he had removed the heat shield! That will really kill battery life, he knowledgeably said, explaining electrolyte evaporation."

auxiliary battery

Franks comments:

"Well the area behind the diesel battery and behind the taillight constitutes a great box of similar dimensions to the primary diesel battery location. As I '83 I began mounting the side terminal batteries here. Bit costly though because just before each major camping season began, I would have to replace the battery. Deep cycle discharge of a non deep cycle battery! Well, I really mean expensive in the sense of time. You have to take out the starting battery to get at the auxiliary. With time, as I explained in a previous post, the Montgomery Wards battery people kept getting increasingly surly over the 2x per year replacement strategy (probably waiting for the lawyers to write an exception into the battery warranty specifically addressed to me!).

Anyway, no deep cycle batteries were available that would fit in the space allotted. Remember, the Optima GelCell RedTop is not deep cycle. Finally I discovered the Nautilus MegaCycle GelCell deep cycle marine battery (made by Exide).

The NC-24 has dimensions of 10 - 3/16 inches long, 6 - 13/16 wide and 9 - 7/16 high. The specs are: 74 minute reserve capacity at 20 amp discharge rate, and 130 minutes at the continuous 10 amp discharge test (60% cell voltage remaining), and 550 CCA at 32 F. Weight is 51 pounds. This battery is marketed by Exide as the Nautilus MegaCycle or the Prevailer."

auxillary battery continued

Frank's comments:

"The battery has a dual terminal setup. I run the main ground and the alternator charging lines to the automotive type terminals and the load lines to the wing nut load terminals. Important, for mounting, I use the battery with top terminals only, and lay it down with terminals facing the taillight. I do all wiring with taillight removed. There is a gap of approximately 1.5 inches from the battery wall to the rear deck flooring. At the rear edge of this compartment I removed a lip of metal that interfered. Used a hacksaw then rubberized the whole compartment. New battery cost was around $70.

Update: Since this original install, Optima has come out with several deep cycle gelcell batteries that will fit this same area. If the Nautilus ever fails, I'll replace it with one of these. Of course, the Nautilus has been so reliable that I forgot how I put it in there. The Optima models are the D900M blue top or the 750S yellow top. The retail on these puppies is around $180. But a better investment than a $700 spare 9 liter gas can to fit in the spare tire.

Oh - afterthoughts: Rigged a rubber retaining strap to keep the battery from shifting about. I use the VW relay approach to switch the battery on and off the primary alternator load, but I use the puny (sorry) VW relay to switch a hefty but inexpensive marine relay (rated at more that 100 amps) to control the actual load. I also use an emergency override to switch in the two batteries in parallel is I feel the need to smoke the GD starter. Haven't done it yet, but I keep it as a threat."

interior

Note propane heater air intake grill to the right of the "wardrobe" door. Device at top corner of "wardrobe" is the heater thermostat.

View of the propane (insert name) heater. Mounted on the outside wall of the "wardrobe". Black tubing on top is cabin air intake, heated air ouput tubing can be seen at the left of he picture. Combustion air and exhaust is via the left rear wheel well.

 "Porta-Potty" hidden in factory option enclosure.

Note propane heater air output grill to the right of the cupboard door.

wheels

Audi 5000S alloys.

Note the top of the AFM on the battery tray, the airbox is tucked in behind the taillight (where Frank keeps his aux battery.

Thats a replacement coolant expansion tank.

Ooh, my neck hurts looking at this one.

Note coil mounted on side wall (my coil is mounted on the old diesel filter bracket which can be seen sitting vacant on Stephen's van).