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Here is a link to one of the Bussman distribution blocks. Five relays, ten fuses, 80 amp capacity per block, 30 amps per circuit (bridgeable to 40 amps per circuit). They make another one that is about twice this size, ten relays and (I think) a 200 amp capacity...

Never use inline fuses if you can avoid it. They are a pain to find and check unless you remember exactly where they are. Bussman makes some distribution blocks that include relays and fuses on a single block. I just got a couple for a project and they look simple but are a big pain to wire...

ARB rack on a fiberglass shell, not mine. Fiberglass is fiberglass. Make sure the top can handle the weight, distribute the mounting points, seal the penetrations well, and use good hardware (I use stainless). I have had one rack on a fiberglass shell for 17 years with no leaks and a lot of...

No makee last time I checked. OP needs to go here for advice: http://forum.powerwagonregistry.org/index.php Yes, they are PW guys, but lots of knowledge and willingness to help.

There is a set of instructions on the Odyssey website for reconditioning their batteries, and I think they recommend taking it down to 10.6V (don't trust my memory on this), and then bringing it back up on one of their chargers. Ctek 7200 may not have enough amperage to do much on that big a...

You only need to do that if the battery you are trying to charge is so low that the charger can't sense that there is a battery attached to it. The second battery tells the charger that it is OK to start charging. If your PM1 is under warranty, get it back to Sears ASAP. If they say it is...

Have you tried the full reconditioning cycle on the Ctek 7200, with the battery disconnected from load? Might take a couple of days, or might not work.

Remember that you should measure OCV on the PM1 after the battery rests for at least 8 hours after coming off the charger. Need to let the surface charge dissipate. Or, you can flash off the surface charge by turning on the headlights for 30 seconds. Fun with batteries!

Everything under it IS coated. No reason not to paint the raw edge of the hole. I used to work for Lockheed.

Belt and suspenders approach. Not required, but better is still better. I try to not cut any corners, and five minutes with a small paintbrush is worth it to me.

You can get away with mix/match, but it's a good idea to use anti-seize with dissimilar metals. And always use anti-seize with stainless because it has a tendency toward galling when torqued. Your installation will be about as strong as the weakest link, so use aluminum in lower stress...

I can probably post pics tomorrow night. The truck with that rack is not with me now.

I have Yakima round bars on my truck and have attached all kinds of stuff with the Yakima keyed locks that wrap around the bars. Everything can go on and off with just a key. Cheaper alternative is to use galvanized thinwall conduit clamps from Home Depot. The Yak bars are about 1.2" (or...

Might just be the wrong tape product. I installed some strips on the inside face of my camper shell back window, black fiberglass, a couple of years ago and the stuff is still as tight as the day I applied it. Lots of time in the sun in So Cal and AZ, parked outside year around, no special...

Here is something similar, but it is $2.30/ft in 1/2" diameter, 50ft spools. I'm going to look around again for the milsurp stuff. http://www.cableorganizer.com/kevlar/

Unfortunately, no. That batch was coiled up in the back of an old auto electric shop, so I grabbed it. Used it all and wish I had more.

I agree that tinned marine cable is preferable, but at what difference in cost? Around here, the tinned marine 3/0 is about $13/foot, tax included, plus whatever the shipping cost would be. I bought a large batch of 3/0 pure copper welding cable for a little over $1/foot on Craigslist, and...

I think the more important issue is water leakage into the interior of the vehicle, with a connection that can be connected/disconnected as needed.

The first one you linked above is available at Home Depot, but it is pretty light duty, not VHB. The second one is also available at HD (I think) and might be VHB, but probably not. The genuine "3M VHB" rolls that I have seen are printed with that logo on the inside of the cardboard core. The...

Odyssey tech sheet says it wants to be above 12.84V at 100% charge. http://www.odysseybattery.com/documents/US-ODY-OM-012_1014.pdf If that is after a fresh charging cycle, it should be higher. from Optima tech specs for G34 Yellow...