2006 Utopia 205 SE Dual Battery Setup
Here's the setup. Sorry I didn't get any pics during assembly.
The base is made from 5x5" vinyl fence posts slotted to fit under the factory battery tray and extended to the aft just forward of the exhaust. Not having access to a welder or the materials, I braced the bottom with galvanized slotted angle iron. I built a three sided platform/box using the heat exchanger bolts as attachment points. I still have to build a rod to slip through the holes in the angle iron to restrict the upward movement of the rear of the tray. There are three pieces of the vinyl post cut to rest on the hull (actually on the steel pieces) and bolted/screwed together. I covered the top with some rubber from a mudlfap. Best I could scrounge.
The new battery tray is a good sturdy nylon piece with stainless rods from Atlantic Boat Supply. All cables are pre-built 4 or 6 ga. Any ends I butted together or put on a terminal myself are the heavy duty terminals crimped with a large vise grip, cold chisel, and BFH. They were then soldered, hot glued and shrink tubing applied.
I still have a little tidying up and cable lashing to do after I get the LED wiring in place.
I still have to run the wire for an LED up to the cockpit, but I was able to locate the start wires in the engine bay. The connector was actually quite simple to disassemble to properly splice a wire to it and get a good seal, again with hot glue and shrink tubing.
After recording or taking a good pci of the wire positions, start by disconnecting the two plug halves. There are squeeze tabs on either side of the plug.
Then, using a 90* pick or dental tool, carefully pull back the rear rubber seal. Work around the edge, take your time, and it will slide back on the wires. There's one pin that is unused and has a small plastic plug inserted. Be careful not to lose this plug.
There is a wedge nose-piece in the business end of the plug. Carefully pry the nose piece out.
Now you can see it is a simple matter of slightly angling the pin you wish to remove and pressing the catch towards the center of the plug slightly as you pull the wire to the rear.
Perform the work that' needed and reverse assemble in the same fashion. Ensure all the pins are fully inserted and try to keep them aligned as you inserted the plug STRAIGHT in. If you cock it off to one side or the other, it will catch on the little catch/latches that hold the pins in. Don't force anything, it should seat with no pressure down to the last 3/16" and then snap in gently.
Re-seatthe rear plug, plug it all in and do a function check your engine9s) still start and run without error.
