Medium Van Build Instructions

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====DC-DC Wire Install====

===Tools Required===
[[Tools:T20 Screw Driver]]\\
[[Tools:Yellow Handle Anderson Cripmer]]\\
[[Tools:Dab Torch]]\\
[[Tools:1/4 inch drill]]\\
[[Tools:number 2 philips long bit]]\\
[[Tools:Nose Pick]]\\
[[Tools:Compounding pliars]]\\
[[Tools:Big Stripper]]\\
[[Tools:Quarter]]\\
[[Tools:Little Dikes]]\\
[[Tools:1/4 Ratchet]]\\
[[Tools:8mm Socket]]\\
[[Tools:Cable Cutters]]\\
[[Tools:Shop Vac]]\\

===Hardware Required===

===Equipment Required===
[[Equipment:6awg x 10 lugs]]\\

===Bulk Items Required===
[[Bulk:6 AWG Marine Wire]]\\
[[Bulk:3/8 heatshrink]]\\

===Supplies Required===
[[Supplies:Electrical Tape]]\\
[[Supplies:Small Zip-Ties]]\\

===Quick Reference===



===Instructions===
  * Remove cover from right side of driver seat. 
    * 3 T20 screws
    * Long one is the upper forward one. 
    * Set Cover and Screws on passenger seat
  * Remove trim at bottom of driver side A pillar
    * Remove 5 philips screws with 1/4 drill and #2 philips bit
    * Use thumb along top of cover to pop loose from upper A pillar cover
    * Wiggle it up and remove. Set on Driver seat along with screws
  * Remove cover from right side of driver seat. 
    * 3 T20 screws
    * Long one is the upper forward one. Pull e-brake to access one of them.
    * Wiggle cover up and over e-brake handle and set cover and screws on driver seat
  * Remove plastic trim panel below dash in driver door opening (photo)
    * Remove 3 philips screws with 1/4 drill and set cover and screws on driver seat
  * Remove plastic step at bottom of driver door opening
    * Start by poping 4 screw covers with Nose Pick
    * Remove 7 #2 philips screws. One behind e-brake needs a long scew driver or long extension on drill. Rest can easily be done with 1/4 drill.
    * Set to the side in a place where it won't get kicked
  * Remove battery cover that is under the drivers feet
    * Use a quarter to turn clips 90 degres and remove cover
  * Pop battery cover off by pressing in 2 clips and pulling up. Slide to the side
 {{build-steps:dc-dc-a.jpg?100x100}} 
  * Pull 8mm nut from 70amp fuse that goes to 6awg wire that runs over to the foot well. This is the wire to the upfit harness that isn’t used with our install. 
 {{build-steps:dc-dc-b.jpg?100x100}} 
    * Pull this wire back and wrap it up and zip tie it in the footwell. The idea is to make it obvious that it is intentionally not in use if someone opens it up in the future. The other end isn't connected to anything so no need to wrap the end with electrical tape.
 {{build-steps:dc-dc-c.jpg?100x100}} 
  * Trim back of wire tray so 6awg wire can run directly back behind the seat.
 {{build-steps:dc-dc-e.jpg?100x100}} 
  * Route wire from spool in cargo area up through the path that was opened by removing the upfit harness
 {{build-steps:dc-dc-d.jpg?100x100}} 
  * Crimp (#10) small end 6awg lug onto new wire after stripping it with big stripper. While holding wire with crimper bend end over 90 degrees like wire end that you removed.
 {{build-steps:dc-dc-f.jpg?100x100}} 
  * Route wire down with a loop and back up through where the old wire was removed. 
 {{build-steps:dc-dc-g.jpg?100x100}}  {{build-steps:dc-dc-h.jpg?100x100}}  {{build-steps:dc-dc-i.jpg?100x100}} 
  * Pop battery cover back on and make sure 2 clips engage. 
  * Put battery floor cover back on after making sure it is vaccumed all around the area and twaist claps 90 degrees with a quarter to hold it in place.
  * Vaccum out area below foot well and re-install it with the 7 #2 philips screws. Will need a long #2 screw driver or long extension for 1/4 drill
  * Reinstall plastic trim panel below dash with 3 screws
  * Re-install left side seat base cover with 3 T20 screws. Longer screw is forward upper.
  * Re-install A-Pillar lower cover by popping in top clip and re-installing 5 philips screws
  * Cut wire at C-pillar (see photo). Wire is live so wrap with electrical tap. Then wrap and put under driver seat
 {{build-steps:dc-dc-j.jpg?100x100}} 

===Stuff we've already tried===
  * We tried using crimps that already had a 90 degree bend and they cost way more and were a little harder to crimp. Using the straight ones and just bending them is only the smallest amount more effort for significantly less money.

===Stuff to do===
  * Make sticker to go on old upfit harness wire - 
  * Length of 6awg wire
  * Sticker for DC-DC wire