Build Thread My Grenadier Trialmaster Utility Build

[Tazzieman]

Well that's reminded me of something I'd forgotten!
Shouldn't void the warranty with that mod

 

[Znarfgh]

SIDE STEPS

Time to start work on the side steps. Will try a design using 50x25x3 RHS for the steps and supports and 4mm plate steel for the mounting plates. The weight should be around 12kg per side which is fine. These will be steps and not rock sliders.

I need to make an L plate for the centre support and will then test the step for strength.

 

[Znarfgh]

BATTERY MONITOR

I have been using a twin voltmeter to keep an eye on the battery voltages but decided to purchase something a little more useful. https://www.ebay.com.au/itm/1957192...pid=5338980679&customid=&toolid=10001&mkevt=1

Installed one on each battery, charged both batteries to 100% and then compared the vehicle readout to that of the monitor.

As others have found, the vehicle gives a different reading to the monitor.

The vehicle says 82% and the monitor 99%. As a test I will let the battery run down to 50% SOC and then compare the vehicle to monitor readout.

 

[Znarfgh]

SIDE STEPS

I worked out a design for the side steps using RHS and some rudimentary welding skills - should be around 20kg per side and do the job.

Materials should come in around $300 and a LotsaDollars for my labour (I'm more a woodworker than metal fabricator!)

 

[Znarfgh]

SIDE STEPS

The side steps make a huge difference to getting in and out of the vehicle. Temporary coat of paint till I decide on the final finish. These should have been the very first modification on the list.

I don't think they will stand up to rocks well but if that does eventuate, I'll build a different set.

 

[Znarfgh]

COMPRESSOR

That portable ARB compressor needs to be hard mounted.

I made up a mounting plate, modified the ARB plate from the portable box and it all fits nicely behind the second battery. I will remove the outlet with a T fitting and put a second outlet on the passenger side. This just makes it easier to get to the van on the passenger side.

Wiring etc. still to be completed but will use the power supply located to the left of the compressor.

 

[Znarfgh]

I have a Gator rearview mirror with the straps and because of the positioning, interferes with the airbag warning on the overhead console.

After some searching, I found a Universal mount that looked like it would fit and ordered it.

Universal Auto Spiegel Dash Cam mit Spezielle Backplate Panel für Auto DVR statt Strap - AliExpress 34

Smarter Shopping, Better Living! Aliexpress.com

www.aliexpress.com

The fit is not 100% but a little modification made it work.

I decided to remove the complete OEM mirror and was left with this.

I had this RAM mount lying around and it holds onto the mirror nut just fine.

Add a couple of these and a 18mm hex nut:

Fanaue Halterungen Adapter 1 Zoll Kugel halterung m6 x 1,0 Pfosten halterung Holl Telefon halter auf Motorrädern Spiegel b Größe 1

Smarter Shopping, Better Living! Aliexpress.com

www.aliexpress.com

And, I have a new mount

No more clearance issues and I can now actually use the mirror part if I so choose

No more clearance issues either

 

[Znarfgh]

PORTABLE BATTERY BOX

Given the unconventional dual battery setup configuration, I decided to add a LiFePO4 battery, DC-DC charger, Bluetooth monitor and battery box to the Grenadier.

It's just a generic battery box purchased off Ebay with a few modifications to suit my power needs. I changed some of the output sockets, the battery disconnect button and the power in socket to a three pin Anderson which takes care of the ignition trigger wire and allows for quick connection. I removed the high output 120A Anderson plug and replaced it with the triple Ando as I have no need for the large Ando which I think was meant for jump starting.

I mounted a 40A DC-DC charger inside the box and put a small window in the lid so I could monitor the charger lights.

The yellow Anderson plug is for a solar panel connection. All my consumers like fridge, additional power outlets, reversing mirror cam and other charging points run off this battery and the original dual battery is pretty much the same as it came from the factory. When the EFB batteries reach end of life, I will reconfigure the system and make use of the space where the current second battery is located.

 

[Znarfgh]

REAR STORAGE UNIT

I used a "Chuckwagon" system from a previous vehicle as it has always worked well for me and after all, if it ain't broke...........

Drawers seemed to be a better option to the blue spacecase and I built a set of storage drawers and a spot for the battery box that I use to run all my consumers.

In with the fridge and drawers. Gas cooker and billies in the shorter, lower drawer, food and miscellaneous items in the top, full length drawer.

The lid needs a tidy up but that's not urgent. It's not new and pretty, but well relatively light, proven and works well for me. Still to come are water storage and a shelf in front of the unit.

 

[Znarfgh]

REAR LIGHTING

Rear lighting for the storage unit is another requirement, and I had a ROK light lying around and decided to fit that.

Added a switch and additional Merit socket to the D panel trim on the small, rear door side for easy access and connected it to the LiFePO4 battery.

Provides a nice amber, bug free light.

Oh, and by the way, the D pillar trim is a right pain to get off and clip breakage is inevitable

 

[Znarfgh]

INTERIOR LIGHTING
In the two-seater the rear lighting is less than ideal, and I added a low cost light to the cargo barrier. Tri-colour and dimmable, it makes a huge difference and has proved to be a very worthwhile addition.

 

[Znarfgh]

MORE REAR STORAGE

The good folks at https://www.euroflo.com.au/the-grenadier made a custom shelf that integrates with my storage unit. I designed it to store lighter items like clothes, and it provides a nice spot for the food warmer as well. Thanks, Justin, for this quality bit of kit.

 

[beg]

BATTERY MONITOR

I have been using a twin voltmeter to keep an eye on the battery voltages but decided to purchase something a little more useful. https://www.ebay.com.au/itm/1957192...pid=5338980679&customid=&toolid=10001&mkevt=1

Installed one on each battery, charged both batteries to 100% and then compared the vehicle readout to that of the monitor.

View attachment 7877078

As others have found, the vehicle gives a different reading to the monitor.

View attachment 7877079

The vehicle says 82% and the monitor 99%. As a test I will let the battery run down to 50% SOC and then compare the vehicle to monitor readout.

sorry if i got this wrong but when you say you fitted one to each battery do you have the factory dual system or is it a custom build ?

 

[Znarfgh]

sorry if i got this wrong but when you say you fitted one to each battery do you have the factory dual system or is it a custom build ?

Yes, factory dual battery setup.

 

[Znarfgh]

Z Case Fuse

I blew a Z Case fuse through user error - at 27 Buckeroonies it was an expensive mistake. I decided to pull apart the blown fuse to see what's inside.

For clarity, this is not the way the fuse is assembled - I just put it together this way to better show that it's blown. I still wonder why these fuses are so expensive - there's not much to them.

 

[Clark Kent]

Z Case Fuse

I blew a Z Case fuse through user error - at 27 Buckeroonies it was an expensive mistake. I decided to pull apart the blown fuse to see what's inside.

View attachment 7915317
For clarity, this is not the way the fuse is assembled - I just put it together this way to better show that it's blown. I still wonder why these fuses are so expensive - there's not much to them.

View attachment 7915318

Presumably quite a lot of money goes into the physical packaging so it can handle the heat and remain stable at higher current ratings. Otherwise it's just another fusible strip of metal.
Did that 27 dollarbucks include delivery?
Swe-check has the 40A for $19.80 but their $15 minimum postage kills the deal.

 

[Znarfgh]

Presumably quite a lot of money goes into the physical packaging so it can handle the heat and remain stable at higher current ratings. Otherwise it's just another fusible strip of metal.
Did that 27 dollarbucks include delivery?
Swe-check has the 40A for $19.80 but their $15 minimum postage kills the deal.

Just checked the invoice from Mouser and the 40A fuse was $29.23 (incl GST) and free delivery - they have free delivery over a certain amount and given my propensity for blowing fuses, I bought a few Delivery was very quick with DHL