| Author |
Message |
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
 Posted: Sat Aug 05, 2017 3:33 pm Post subject: Kill switch and jumper terminal install |
 |
|
Greetings all. This was my morning project and for the mid-level to beginners like myself I thought I'd post up my experience installing a fresh battery and kill switch and jumper terminals. I had the three projects. I previously purchased and install the VanagonLife console on the first group buy.
http://www.vanagonlife.com/theshop/locking-steel-center-console
I knew eventually I wanted to do the Blue Sea kill switch that Dave designed the console to accomodate.
As I began thinking about that, I knew I also wanted a new battery (yep, the Walmart one) and a set of Terry's jumper terminals.
http://vanagonwestfaliaaccessories.com// (scroll down)
For the kill switch, I ordered a red one, I like red. I also had Dave send me his kill switch kit which I must say is simple but very very nice. Includes awesome cables with lugs installed and abrasion guards on, plus the perfect machine screws to mount the switch and some grommets.
https://www.bluesea.com/products/category/11/37/Manual%20Battery%20Switches/m-Series
http://www.vanagonlife.com/theshop/console-accessories
Step one was getting the grandparents to watch the toddler so I could concentrate.
This is what I started with:
Here's the pics of the VanagonLife install kit and my switch and Terry's jumper terminal I had already bolted down. Terry doesn't play. You already know that. He got me a kit out in a few days and I can't believe I've gone all these years without a remote jumper terminal.
Next I pulled the battery and cleaned up the box and the endless supply of mouse poop. You can see the left black panel. I did a 1/4 battery box mod and just drilled out about 5 rivets and removed this panel so I can see if I could drill form the inside. I could not but I don't have a pic.
I had hoped and hoped I wouldn't have to remove the console I previously installed to drill the 1" holes through the pedestal to run the kill switch cables but alas, after I got the battery box out and drilled out the left side battery box panel, I discovered it was a no go. The holes had to be drilled from the exterior.
So, that was an hour setback undoing my wires, the seatbelt receivers, and moving the console. But this allowed me to reach into the console with a sharpie and perfectly mark the holes.
And remove the console and drill:
After the holes were drilled I cleaned em up with a file and lube and stuck in the grommets from Dave's kit. Essential. Then I ran the cables into the box and mounted the switch:
After that, factory ground strap gets removed and one end from the kill switch takes its place. The other cable to the battery.
Dropped in the new battery and then spent a while getting all the fittings oriented the way I needed them, including at this point mounting the lugs from Terry's jumper kit. His cables are dead on with little margin for error regarding slack. Basically I didn't show it because the finish work is spaghetti but I drilled out the top of the battery cover to allow clearance for the jumpers and voila. Done and the Van even started with the switch on position.
I know, some real detailed types are screaming what I learned too. Basically the jumper terminal would bypass the kill switch if a thief were to be prepared for that. But, I think this solution works for me. For anyone looking to add the kill switch to their console, just get Dave's kit. It makes install brainless mostly. His lugs on his cables only fit one way, meaning one size lug fits his provided negative batter terminal clap and the other lug fits the factory bolt for the ground in the box. Just check your ends first and then connect to the switch etc. as the switch is marked battery and common! I can sleep a little better now!
Next up, talking to theadventureneverends for help with Thule ARGs, Jack Bombays and clearing a Fiamma!
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
 |
theadventureneverends
Samba Member
Joined: December 24, 2009
Posts: 585
Location: Gig Harbor WA
|
| Posted: Fri Aug 11, 2017 8:16 pm Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Stoked on the detailed write up you did! I finally installed the console about a week ago. It was painless. I had just enough time to install prior to our road trip which did not happen. The kill switch will be my next job and while there better do the remote jumper as well!
I am on the fence between a single and double battery switch from blue sea. Dave uses a single and is happy with it. I will be adding another battery under driver seat at some point so maybe a dual switch now is a good call?
Any more pictures of your install?
If you are still planning on ARGs, Fiamma, and JBs feel free to call or text if you have any questions about my measurements pm me for my number. |
|
| Back to top |
|
|
IdahoDoug
Samba Member
Joined: June 12, 2010
Posts: 10251
Location: N. Idaho
|
| Posted: Fri Aug 11, 2017 11:05 pm Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Following this.
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader |
|
| Back to top |
|
|
Bills85Westy
Samba Member
Joined: August 01, 2009
Posts: 423
Location: Napa CA
|
| Posted: Sat Aug 12, 2017 12:03 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Hey Chris,
Thanks for showing me your setup in person today! I'm now rethinking my house battery setup and storage.
Bill
_________________
89 Tristar Syncro Doka - White
85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L |
|
| Back to top |
|
|
djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32633
Location: Reading Pennsylvania
|
|
| Back to top |
|
|
Abscate
Samba Member
Joined: October 05, 2014
Posts: 22670
Location: NYC/Upstate/ROW
|
| Posted: Sat Aug 12, 2017 2:06 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Is there enough room in the box to mount the switch do that the cables run internal rather than through the ajar door?
Aesthetics, but also chafe protection.
_________________
.ssS! |
|
| Back to top |
|
|
djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32633
Location: Reading Pennsylvania
|
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Sat Aug 12, 2017 7:36 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Another note you'll see my jumper terminal I added the rubber boot cover thing. It was about $6 on Amzn but I didn't want to leave it exposed. Terry's kit didn't include and that's the only shortcoming.
Agreed about the vapor tank. I crawled all around the wheel well trying to insure I wasn't going to screw into anything. I couldn't really see so based on Terry's advice I just went for it and tried to drill some shallow pilot holes for the screws. Seems to be good.
Abscate I'm not sure if this answers your question but the console box is pre cut with 2 1" holes about 1/2 inch apart. Each cable from the kill switch passes through its own hole and included grommet into the holes I drilled in my pedestal. No external routing. Were you asking about mounting in battery box? That might work if you remove the box panels and open it up. I don't have pictures of my drilling out the rivets and removing the one panel.
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32633
Location: Reading Pennsylvania
|
|
| Back to top |
|
|
WestyWanderlust
Samba Member
Joined: July 11, 2017
Posts: 7
Location: Seattle
|
| Posted: Tue May 21, 2019 5:34 pm Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Thank you for this write-up! Can you please clarify the following:
1) When you drilled the holes from the exterior to the battery box, what size drill bit did you use?
2) When you drilled the holes through the second wall on the inside of the battery box (from the interior), which size drill bit did you use?
3) On attaching the cables from the shut-off box to the battery, did you put the "input" wire to the positive battery terminal and the "output" to the negative battery terminal? I was not sure of this and the shut-off box company website is not to clear on that as it is specific to the Vanagon.
Thanks in advance for your help here! |
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Tue May 21, 2019 8:29 pm Post subject: Re: Kill switch and and jumper terminal install. |
|
|
| WestyWanderlust wrote: |
Thank you for this write-up! Can you please clarify the following:
1) When you drilled the holes from the exterior to the battery box, what size drill bit did you use?
2) When you drilled the holes through the second wall on the inside of the battery box (from the interior), which size drill bit did you use?
3) On attaching the cables from the shut-off box to the battery, did you put the "input" wire to the positive battery terminal and the "output" to the negative battery terminal? I was not sure of this and the shut-off box company website is not to clear on that as it is specific to the Vanagon.
Thanks in advance for your help here! |
Hey there. Yes I should have documented better as now my memory is a little fuzzy. If I recall, I must have used about a 1" or larger hole saw like this:
https://www.amazon.com/LENOX-Tools-Bi-Metal-Arbore...T5FQ4S5KX1
I just matched up a hole saw from my tool box to the closest size of the holes already cut in the console. You can see the red pen marks I made in the pic on the gray carpet. Oh and I only recall having to drill one set of holse from the box. I think I just drilled out some small rivets holding the interior metal pieces of the box together, and with the piece of the box out of the way, it's mostly an open shot out of the pedestal.
As for the switch, it's basically a ground cutoff. So you'll run your ground cable from the body to the switch IN, and then another cable from the switch OUT back to connect to the battery. When the switch is off, the battery therefore has no ground connection and so the electrical is cut. Hope that helps.
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
WestyWanderlust
Samba Member
Joined: July 11, 2017
Posts: 7
Location: Seattle
|
| Posted: Fri May 24, 2019 10:04 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Thank you so much @Vnyd Dog! That is super helpful. I am excited to get this completed today!
Last edited by WestyWanderlust on Fri May 24, 2019 11:14 am; edited 1 time in total |
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Fri May 24, 2019 10:59 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
| WestyWanderlust wrote: |
| Thank you so much @Vnyd Dog! That is super helpful. I am excited to get this competed today! |
No worries. Good luck and shoot me a PM if you run into any glitches. Once you dig into it it'll make sense I'm sure, assuming you're using the kit from Vanagon Life. That's what my thread was based on.
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
michaelbteam
Samba Member
Joined: June 28, 2012
Posts: 232
|
| Posted: Sat Aug 17, 2019 11:32 pm Post subject: Re: Kill switch and and jumper terminal install. |
|
|
I'm in the middle of this installation, on a Syncro. I appreciate this write up, since no real instructions came with my kit. As you all know, there is precious little extra room in the battery box for extra cables.
I may be missing something, hence my remarks. I had to drill through two layers of sheetmetal, one thicker at an angle, [is Syncro different here?] to get to the battery box after removing the console. My carbide hole saws didn't like the angle cut and I fried two of them. I suppose I could have drilled the inner layer from inside the battery box.
I'm challenged trying to mount the switch box in the console, after installing the battery with new cables. The switch box is a tight fit with the heavy cable since the mounting position is tight in the rear corner of the console, and I'm having trouble lining screws up with the threaded holes. I would not think it should be this hard.
I ended up with some extra cable in the console; I may actually take out the battery and mount the switch securely first, then install the battery and stuff the extra cable around the top edge.
Feedback is welcome, however "obvious!" I'll finish this installation tomorrow.
If the kit included some "suggested" cable routing instructions, it might make this a little more straight forward.
Otherwise, no complaints about the console or the switch kit. Top quality! |
|
| Back to top |
|
|
dart330
Samba Member
Joined: July 19, 2004
Posts: 454
Location: Houston, TX
|
| Posted: Sun Aug 18, 2019 6:28 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
I'm about to tackle this project as well. Got the center console in the group buy a while back and love it. I'm more concerned about an emergency kill switch in case of fire than anything else.
More pictures and info on what size drills used to get into the battery box would be really helpful if others could share. |
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Sun Aug 18, 2019 6:50 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
| michaelbteam wrote: |
I'm in the middle of this installation, on a Syncro. I appreciate this write up, since no real instructions came with my kit. As you all know, there is precious little extra room in the battery box for extra cables.
I may be missing something, hence my remarks. I had to drill through two layers of sheetmetal, one thicker at an angle, [is Syncro different here?] to get to the battery box after removing the console. My carbide hole saws didn't like the angle cut and I fried two of them. I suppose I could have drilled the inner layer from inside the battery box.
I'm challenged trying to mount the switch box in the console, after installing the battery with new cables. The switch box is a tight fit with the heavy cable since the mounting position is tight in the rear corner of the console, and I'm having trouble lining screws up with the threaded holes. I would not think it should be this hard.
I ended up with some extra cable in the console; I may actually take out the battery and mount the switch securely first, then install the battery and stuff the extra cable around the top edge.
Feedback is welcome, however "obvious!" I'll finish this installation tomorrow.
If the kit included some "suggested" cable routing instructions, it might make this a little more straight forward.
Otherwise, no complaints about the console or the switch kit. Top quality! |
Now you’re on the right track. Did you first remove the battery box walls? Those thin gauge black metal pieces that are riveted in? That’s the first trick. I don’t think you could do it otherwise.
For the switch what I did was slide the console out of position down about half way. I put the switch on and ran the cables out of the console and over into their new holes in the pedestal. The I slid the console back up the center and pulled cables back into battery box and fitted everything back together. I think also with console out you’d be having an easier time mounting the switch in there.
As for hole size, I seem to recall it’s somewhere between 1 1/8” or maybe a touch larger. You can’t mess up.
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Sun Aug 18, 2019 6:54 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
Ha! I even found my email from Dave when I had the same question:
Afternoon Chris,
The through holes for the console and grommets are 1". We use a 1" hole saw for this when we install them here at the shop.
Cheers
Dave
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
michaelbteam
Samba Member
Joined: June 28, 2012
Posts: 232
|
| Posted: Sun Aug 18, 2019 7:10 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
The limited instructions with the kit call for a 1" hole saw, and two rubber grommets are included for the two holes to be drilled through to the battery box, matching the holes already in the console. [Although I ended up with 4 holes, through two layers.]
I had some carbide hole saws leftover from a plumbing project and used those, which were destroyed. I think you could easily cut small square openings with metal jigsaw blades or even a Dremel with a cutting wheel, which I used to clean up my holes.
I like the kit from Vanagonlife but you could make your own and mount the switch anywhere.
As I complete this adventure later today, I'm sure the process will finally become clearer to me me. Later. |
|
| Back to top |
|
|
Vnyd Dog
Samba Member
Joined: August 25, 2015
Posts: 384
Location: Napa
|
| Posted: Sun Aug 18, 2019 7:48 am Post subject: Re: Kill switch and and jumper terminal install. |
|
|
| michaelbteam wrote: |
The limited instructions with the kit call for a 1" hole saw, and two rubber grommets are included for the two holes to be drilled through to the battery box, matching the holes already in the console. [Although I ended up with 4 holes, through two layers.]
I had some carbide hole saws leftover from a plumbing project and used those, which were destroyed. I think you could easily cut small square openings with metal jigsaw blades or even a Dremel with a cutting wheel, which I used to clean up my holes.
I like the kit from Vanagonlife but you could make your own and mount the switch anywhere.
As I complete this adventure later today, I'm sure the process will finally become clearer to me me. Later. |
Um Jigsaw? No offense but you’re over thinking this. Here is the only tool you need for holes like this:
https://www.amazon.com/LENOX-Tools-Bi-Metal-Arbore...amp;sr=8-3
Zips through in about 5 seconds.
_________________
'87 Westy 1.8T Conversion, Orignal Owner, European Delivery @ Westfalia factory in Weidenbrueck.
The Story:
https://www.thesamba.com/vw/forum/viewtopic.php?t=713391&highlight=life |
|
| Back to top |
|
|
michaelbteam
Samba Member
Joined: June 28, 2012
Posts: 232
|
| Posted: Sun Aug 18, 2019 10:36 pm Post subject: Re: Kill switch and and jumper terminal install |
|
|
Thanks Vynd Dog: that's exactly what I used. Did you drill through two walls? Sounds like perhaps you drilled rivets and removed inner wall. You made it sound simple and easy.
My hole saw went quickly straight through carpeted outer thin wall; to keep same path, the thicker inner wall was contacted at an angle which burned up the drills quickly, although I got through. The main question I have is about tight cable routing into the switch, making it difficult to screw switch screws into the console. I can certainly do it but did not expect it to be so difficult.
Puzzling this out here to see if anyone has other experience with this installation to share.
I'm no stranger to challenges like this. If I can figure out an error it may save someone else trouble.
Minor problem. |
|
| Back to top |
|
|
|
