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Fitting a split charge relay with wire through bulkhead

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Fitting a split charge relay with wire through bulkhead

Postby theredcaddy » Tue Oct 09, 2012 6:55 pm

Having followed this thread, I thought I'd post how I fitted a split charge relay kit to my connect.

I used the grommet found behind the N/S wheel arch liner, and pierced through to the cab (just behind the glovebox, but safely away from the wiring)
you can see where the ribbed conduit (marked with red tab) then runs up into engine compartment
Image

I fed the conduit up and through to near the battery: (red flag on conduit again)
Image


Back inside the cab, you can see where the conduit comes through into the footwell:
Image
Image


From here I ran the cable along the inside of the centre console, and out to where I've put the intelligent split charge relay. In the top of the picture you can see where I've added a new earth point also. I removed the paint to bare metal, then coated with copper grease to make sure contacts were good and won't rust.
Image

    The split charge relay kit I used is from eBay, (item no.180974394125) It is ok, but there are a few niggles with it:
  • There is only just enough cable to run to the relay and battery (4m), and there is no black wire supplied (I think the same amount of black wire should be supplied also(?)
  • The fuse holder supplied are rubbish. They are the self cutting type, not waterproof, and are very flimsy. (it didn't cut into the wire properly first time >:-( )
  • The ring connectors are too small, I had to use a larger one to connect onto my battery

Having said that, all the circuits work as they should (though yet to test fully). I have used a kit like this on a previous van, and it kept my secondary battery charged perfectly well for me then, so I'm assuming this will do the same. (Though I don't remember having the same niggling problems as above.)

The conduit I bought is from here (eBay item no. https://www.ebay.co.uk/itm/261075229579) A good price I thought!

Tips I've learned if I were to do the job again:
Buy extra wire and conduit before starting! (probably 6 metres at least, maybe buy 8m to be sure).
Feed cable through conduit before installing conduit (trying to thread the wire through the bends in the conduit was a pain!)
Have spare connectors on hand.


I hope that's of some help if anyone else is thinking of doing a similar job!

:)
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Re: Fitting a split charge relay with wire through bulkhead

Postby Mylee » Tue Oct 09, 2012 7:33 pm

Why have you got a fuse so close to the relay?
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Re: Fitting a split charge relay with wire through bulkhead

Postby theredcaddy » Tue Oct 09, 2012 8:39 pm

The second fuse is supposed to go close to the second battery, and the battery is just the other side of the bulkhead. I thought it would be better to have the fuse accessible from the cab rather than hidden in the corner of the cargo area so I put it there!
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