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Old 08-27-2017, 12:24 AM   #1
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Be Prepared For A Nightmare Install!

I you have a coach that was built with two 12 volt batteries (under the step), do yourself a favor.
Don't install four Taller 6 volt batteries yourself! (but, I don't think an RV shop would do it for you either.)
Or, Stick with the shorter 12v units if you go with four batteries.
Then, to add insult to injury, the wiring under there is a huge vipers nest! Things could and should have been routed alot better!
I'll just leave it like this, unless somebody REALLY wants "The Rest of the Story". (Paul Harvey)

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Old 08-27-2017, 12:34 AM   #2
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Que?
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Old 08-27-2017, 07:37 PM   #3
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Que?
??
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Old 09-22-2017, 11:58 PM   #4
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The popcorn just finished.
Go onnnn.
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Old 09-23-2017, 12:12 AM   #5
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??
Spanish for "what?".
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Old 09-23-2017, 12:26 AM   #6
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What IS the rest of the story?
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I'm wearing trifocals now but my hindsight is 20/20.
*************
Bilsteins and Sumos front and rear...HUGE! FatMat and Hoodliner...HUGE!
Hellwig sway bars F&R, 235/85 Hankook ATM, alignment...HUGE!!!
Battery watering, 260watts Solar and BigFeets to make life easier.
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Old 09-23-2017, 12:27 AM   #7
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I want to hear about how a tape measure played into the story!
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Old 09-23-2017, 03:01 AM   #8
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I finished the install today. Yes, there was a tape measure involved. I knew the 6v batteries were taller, about 1 1/2". Two fit under the step just fine. Four however, were a problem. I had to "clearnce" the underside of the step on one side. This allowed me to slide one battery straight back, then push it to the side. I had the cables already installed. I then had to install the "quick-fill manifold by feel. Same procedure for the next hidden battery. The front two batteries went in normally. It took me about 6 hours today. I probably spent 5 -6 hrs previously.

https://imgur.com/itbil3o

https://imgur.com/6Bk1EXI
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Old 09-23-2017, 06:26 AM   #9
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Yow, that's a tight fit alright. Would you detail the "clearance" effort? Did you have to fabricate any framework? How are your batteries secured?
Very nice!
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I'm wearing trifocals now but my hindsight is 20/20.
*************
Bilsteins and Sumos front and rear...HUGE! FatMat and Hoodliner...HUGE!
Hellwig sway bars F&R, 235/85 Hankook ATM, alignment...HUGE!!!
Battery watering, 260watts Solar and BigFeets to make life easier.
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Old 09-23-2017, 10:30 AM   #10
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You just made up my mind. I will stick with the group 27 12 volt batteries. If I add, will only add one and turn all of them. Will certainly have to add the quick fill because access to check water levels will become obstructed. Thanks for the pictures.
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Old 09-23-2017, 02:30 PM   #11
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I've never heard of this "quick fill manifold". How does it work?
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Old 09-23-2017, 04:41 PM   #12
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It sounds as if you did NOT have much fun...

Can you post some pictures of your results?
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Old 09-23-2017, 05:41 PM   #13
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WARNING: Novel ahead!

Quote:
Originally Posted by gnach View Post
Yow, that's a tight fit alright. Would you detail the "clearance" effort? Did you have to fabricate any framework? How are your batteries secured?
Very nice!
I didn't need to fab any framework. Right now they aren't secured. They can't go up or down or side to side, just forward or back. I will use some 2x4 or Trex left from our deck to wedge in front and back of them. In picture #2 where the last battery isn't installed you can see the red cable that both ends go under the step. From that area back for about 2" - 2 1/2" there is an area with a 90* aluminum trim piece and the black plastic trim you barely see in the pic. On the left hand side I cut about 6"- 7" of the aluminum trim off to remove possibility of grounding positive post to ground. All of the material removal was done with a 90* die grinder with a cut-off wheel. I then went straight up removing roughly 1/2" of the black black plastic & plywood that was under the aluminum trim. I also cut about 1/4" off the battery post/studs to let them slide into place. And, to my delight (LOL) the quick-fill system has a lower profile than the original battery caps! So, set one battery in (with cables in place) on the left side push back, then slide to the right back corner.Set another battery in the left side, push it back. Then, blindly install the quick-fill manifolds. Set the last two batteries in place and connect all the cables. I have five(5) cables to attach to one positive battery stud, so I made a secondary stud with a z-bend to connect 3 of the cables too. I will now recover from the cuts & bruises for a few days before securing the batteries & zip-tying the last of the stray wires! LOL
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Old 09-23-2017, 05:45 PM   #14
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Quote:
Originally Posted by jb1911 View Post
I've never heard of this "quick fill manifold". How does it work?
Several manufacturers; this is one:

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Old 09-23-2017, 05:50 PM   #15
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Here is a pic of a main wiring cable that I found on my first excursion under the MH. The factory decided NOT to move it before crushing the $hit out of it when welding the battery tray in place. I used my die grinder to cut out a relief and get it out of there. I zip tied it up out of the way.

https://imgur.com/a/66Kcj
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Old 09-23-2017, 05:53 PM   #16
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This the quick fill system I used. Nice low profile caps.
https://www.amazon.com/Flow-Rite-RV2...atering+system

And, instead of spending $27 bucks on their hand pump I bought a $6 pump off ebay!
http://www.ebay.com/itm/8MM-Fuel-Pum...-/292207665909
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Old 09-23-2017, 07:54 PM   #17
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Nice to have a good DC supply! Hopefully you'll get many years of very low maintenance out of it before you have to revisit the cuts & bruises routine again ... aw something else to grin and chuckle about but so worth the journey ...
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Old 09-23-2017, 08:14 PM   #18
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Quote:
Originally Posted by 99dart View Post
I didn't need to fab any framework. Right now they aren't secured. They can't go up... snip
... I will now recover from the cuts & bruises for a few days before securing the batteries & zip-tying the last of the stray wires! LOL
What a YUGE effort!!! Thank you for the procedural narrative and photos, you've made it so clear.
Obviously, Thor could have made this much better but to deliberately crush a cable, welding it in place, guarantees a massive failure in the future. We pay large sums to be Thor's Quality Control Inspectors.
Would you mind posting a couple more pixels of the finished install. Kudos and thanks again.
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I'm wearing trifocals now but my hindsight is 20/20.
*************
Bilsteins and Sumos front and rear...HUGE! FatMat and Hoodliner...HUGE!
Hellwig sway bars F&R, 235/85 Hankook ATM, alignment...HUGE!!!
Battery watering, 260watts Solar and BigFeets to make life easier.
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Old 09-24-2017, 01:51 AM   #19
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If I hadn't just spent $300 on two new 6v batteries in May I probably would have stayed with 12v units. But, I thought two 6v batteries would power our residential fridge over night. They didn't, so that's why such a huge effort getting four 6v to fit. I really don't have any different pictures. The others were bad.
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