Aux Switch, 12V DC2DC and 110V Inverter Install

[haleme]

I finally got around to finishing up the Aux Switch install on my 2500 this week.

My plan for the Aux switches was to use #1 and #2 to switch on power for a DC2DC charger on my travel trailer and an inverter to run a 110V outlet in the bed. Switches #3 and #4 are for rear spot and rear fog lights respectively.


I custom built a wiring harness to send the power to the rear.
Invert is 500 watts (41 amps max) and used 6 AWG wiring. It is wild that the inverter came with 10 AWG direct to battery cables.
DC 2 DC charger is 20 amps and uses 8 AWG wiring.
2 runs of 14 AWG for the rear lights.

I have two big 120 amp relays for the two power points. These relays are controlled by the aux switch relays in the black box to the right.



Everything goes through a 70 AMP fuse mounted on the existing fuse box.


And the wiring from the rear to the front
Started with a harness I made to take power from the relays in the engine compartment to the rear of the truck.

The TRAC connector for the DC2DC charger mounted in the rear bumper.

The wiring harness followed the factory wiring along the frame to the engine bay.


Used an existing hole in the internal bed frame to ground everything out.

I stubbed out the 12V positive for the inverted I will install in a future post.


Finally the rear spot and fog lights are incorporated into an OPT7 60" tailgate light bar. Attached with Neodymium Bar Magnets.



It felt like a lot of work for very little to show, but I know it will be worth the time come our next camping trip.

 

[GTyankee]

Nice clean job with running the wiring

 

[haleme]

Got to complete and test the DC2DC charger this evening. Long story short, it works perfectly!

Need to wrap the cables, but that is a tomorrow job


The DC2DC charger is the blue black box on the bottom right. The box on the back wall with all the wiring has a remote switch I can use to turn the charger on and off from the cab. Going to get this remote synced up to the Home Link button.


And the success, 20 amps from the charger and 5ish amps from the 7 pin connector.

 

[haleme]

Finally got around to install the inverter in the bed of the truck this week. I'm using a Cobra 500 watt unit inside a sealed box mounted behind the left tire.

From the bottom.

And the control unit and 110V outlet in the bed.

It works!

 

[tnctx02]

Awesome write up! Lots of good information and really nice job!
I plan some of these myself and I will use your post as a guide!
Thanks for taking the time to do this!

 

[Wild one]

Awesome write up! Lots of good information and really nice job!
I plan some of these myself and I will use your post as a guide!
Thanks for taking the time to do this!

Garden Hose makes a great hose covering,a little better then the convulated covering the OP used.A long piece of wire makes a great fish tape to pull your wiring through the garden hose.