#82 | DC to DC Charger Install | Chevy Express VanBuild

[@USA-GreedyMenOfNoIntegrity]

2020 Exp 2500, 110A Alt: Installed Victron 12-24V/15A isolated smart charger. 6ga fine wire battery cable, 6ga X 1/4” hole lug, from B+ under DS, 50A maxi fuse within 6” of B+ stud, used a add-a-circuit fuse tap for IGN on power from F13 Fuse- (Rear HVAC & Mirror Defogger Switch), 100A hall current sensor at alternator output cable, meter in spare plastic blanks in dash, thermistor temp sensor epoxied to top rear of alternator with conductive epoxy - meter in dash, switch by meters to turn off at night if needed for driving, switch in overhead to control charger depending on alt temp/current draw. Keep under 83A (75%) and 90°C for longer alt life. There is a 125A megafuse at engine compartment fuse box that supplies power back to driver seat fuse box. My charger pulls about 37A. Remember, these vans can also be wired to have rear window defogger and rear blower. If you are like me and do not have those options, then right there is about 30-40A of extra power available under the driver seat. I would not put anything that draws more than 40A on that B+ terminal.

[@EricPLandry]

I just want to add a warning that using the connection from that fuse box isn't a great idea. The cable feeding the fuse box was engineered and sized to feed the fuse box and maybe a few extra accessories but adding a 60A draw is a fairly large load. Also don't consider this connection for a large inverter. You will cause problems and potential fire.

[@andrewmartin6404]

I have a 2021 ram pro master and for the d+ wire I just used the 12volt power outlet aka cigarette outlet in the back of the van works perfectly. And if I don’t want to use the charger I just unplug the cigarette outlet.

[@desiraeguenard4732]

That was incredible to watch! And yes, congratulations to Chris who has since been doing really well in his driving lessons! Woop woop!

[@VanlifePLUS]

Thanks Des!! And yeah, a big ‘ol cheers to Chris! 🍻

[@domandroid]

For anyone in canada watching this video, I bought most of my cabling for the electrical system of my van at princess auto! For larger gauge they don't have red/black but that is an easy fix with colored heat shrink tube!

[@DuaneCampbell-pu3xp]

Nice job I learned a lot now I can do the one I bought

[@ils360]

A great secret for getting loom over wire Stick all your wires through a box and wrench Stick that in the loom holding the wires at the end of the loom push the box end wrench to the other side It does an amazing job at putting the wires into the loom

[@TheLoneBirb]

This was monumental! I'm currently building a chevy express, and DID NOT want to go through the fire wall. you've helped me think outside the box, or rather "inside the fuse box." lol

[@VanlifePLUS]

Thanks for watching! And I can confirm it hasn’t given me any issues since 😊

[@USA-GreedyMenOfNoIntegrity]

It’s easy to go through the firewall. There is already a 1.5” hole punched and plugged with rubber cap in upper forward drivers side under dash area. I installed 1.25” sealtite fitting and 6” of tubing forward of firewall for present/future use. Just seal up around wires to keep water/insects out.

[@raphtze]

love it brother. in the process of upgrading to lithium batteries for my class C RV with a chevy 4500 chassis. so this is perfect for me :)

[@ronethridge9875]

Alright thanks much 😮😮😮😅😅😅😅

[@keithdawe4866]

Thank you...this was very informative because I will be installing one next week

[@SilverStreakerVids]

Great video! Gave me the courage to do it myself this past weekend.

[@VanlifePLUS]

That’s awesome! Wasn’t too bad eh? Thanks for watching and I’m glad I could help nudge you 😊

[@beyouvanlife]

Congrats to your channel exploding. Love this video and so helpful as I am looking for a van to convert. Have a awesome day.

[@NomadicNannie]

Appreciate this video. It’s been a struggle

[@VanlifePLUS]

Thanks for the comment, glad it could be of some help. Electrical stuff like this is always a challenge - I hope you’ve gotten yours sorted out! 😃

[@philrebekah4286]

Great video!! New subscriber and I love that Spyderco knife. Cheers from Toronto Canada!!

[@VanlifePLUS]

Hi Phil and Rebekah! Welcome to the channel 😊

[@DestinationVanlife]

The is for the shout out buddy. Was a good day for both of us lol

[@VanlifePLUS]

Ya man! Haha. Proud of you dude!

[@DestinationVanlife]

@@VanlifePLUS one step closer to vandome

[@Moola48]

Congratulations Chris. So proud of you. I hope you are enjoying your lessons.

[@Camaro-Sean]

Great electrical work. Very impressive.

[@NFSgamingEvo]

Now i know where to get 12v from accessories fuse box under the seat

[@cmacmillan1980]

Really appreciate this. I'm about to do the same on my Express and wanted to check back and see if you've had any trouble with the setup that I should watch out for

[@VanlifePLUS]

No issues with this setup yet. Charger works everyday and hasn’t presented any problems 👊

[@kyvirlogistics4993]

23:37 they make a wire loom insertion tool

[@eek4904]

Yay Chris!

[@keithdawe4866]

Thank you

[@NYCamper62]

Might be a good idea to add a switch to the line connected to the power / on indicator. Otherwise your drawing a load as soon as the vehicle starts on cold parts.

[@olejacobstalesen6558]

Very enjoyable video - and I love your attitude! I'm thankful for Chrome hauling you into his universe, and look forward to following along! Build-videos are great!

[@tonyyost7125]

Thanks 👍 needed the info.....t

[@wastedyears6653]

Do not use the fuse box as your connection point... someone else already commented about this below and referenced the amperage draw. Its sketchy at best and dangerous at worst.

[@VanlifePLUS]

Worked and is still working just fine 3 years later

[@ankgee]

These cables get warm. Any thoughts??

[@bonniejackson1321]

over my head but hey, good on ya

[@justinhuestis2891]

Hey that looks like my Canadian tire on McLeod. Go up the road to ARA car Audio and you’ll get the best cable.

[@giorgio.plazzotta]

questions: if i decide to activate the DC/DC manually instead of having an automatic start from the D+, do you think i could give this impulse coming from any manually operated source, such as, for example, also a small cable coming from the start battery+switch instead of kicking my ass finding a power source in the fuse box? thanx

[@mtlh05]

Do you still have your charger installed this way?

[@ankgee]

Why add the extra 10amp fuse?

[@yahya_bin_hamad]

I installed the device but it does not give more than 13.2 volts why?😊

[@mattblab9146]

Hey I have the same vehicle and I'm wiring the dc to DC charger the same way. What size fuse tap did u use?

[@VanlifePLUS]

10A

[@sasmicky71]

Jump cables will melt over time on good for that

[@VanlifePLUS]

They haven’t yet in over 3 years

[@badactor3440]

I tested my unit before mounting it just like you did and I can't get the green light to stay on. It comes on for a split second and goes off. I can't figure out why it's happening

[@JamesJReid]

were there any long term problems with the power connection at the fuse box?

[@VanlifePLUS]

So far no, charger still works great over a year later

[@JamesJReid]

@@VanlifePLUS Thanks for the fast response. Your video has inspired me

[@marionsutcliffe1119]

Forestry Forest had his fuse tap burn out ... Kind of put me off them

[@USA-GreedyMenOfNoIntegrity]

If you find a circuit that comes on with the ignition, all you have to do is take a clamp on amp meter or a standard digital multimeter and test the current draw while everything is on in the van and see what goes through that circuit. If it has 10A fuse and you’re pulling 2A, then you can add a 5A fuse with no problems. That ign on circuit to a charger draws very little current. I would limit the current draw two less than 40A on that big 6 mm B+ terminal sticking up.

[@craigeldridge2695]

Hi, very helpful video. I'm converting a 3500 Express Cutaway short bus. My question I'm planning on running a 2000w inverter in my system. Will this set up with picking up the power under the seat be doable?

[@VanlifePLUS]

Well I wouldn’t wire that inverter to the engine battery….I have the same 2000w inverter now and it runs off my House Batteries

[@craigeldridge2695]

@@VanlifePLUS No, it's attached to the house batteries. Thanks.

[@USA-GreedyMenOfNoIntegrity]

It is doable if you install a DC to DC charger and limit the current draw to less than 40A. A 6ga wire with a 50A Maxi fuse worked nicely for me.

[@robint01]

🎉😊🎉

[@MisterMechanicV]

Could have accomplished this for $50 with a split charge relay. Way cheaper, and it's actually designed to do what you're attempting to do. A DC-DC charger is meant to run from your inverter to your house battery when you're on shore power. Not to charge from one battery to the other, although it works obviously. You want a secret for doing loom. Straighten out a wire coat hangar, electrical tape your wire to it, then shove the hard coat hangar through your loom and it pulls the wire with it. Then untape your wire once it's through the loom, and yank out the hangar.

[@donutsmademefat4690]

No this is not designed to run from the inverter. What are you smoking?

[@keepamericayisraelgreat5708]

Good JOB! Kinda like what I do check twice cut twice Yuck

[@vwdiscovery]

Love the video, just a quick one, have you a brother who is a Gold miner ?

[@VanlifePLUS]

I do not, no

[@eddielehman8960]

I just bought a Renogy 20 amp and the instructions said to place the charger as close to the house batteries as possible. How far is your charger away from the house batteries?

[@VanlifePLUS]

About a foot and a half I’d say. Maybe 2 feet. Both the batteries and the charger are under my bed

[@robint01]

😻😻

[@eek4904]

So impressed by you! Great work! You lost me through most of your explanation (is why I hired a professional for my electrical).

[@albertaadventures7750]

Awesome video. Do you have a high output alternator. I’m trying to figure out how to do this but worry I need a high output alternator

[@VanlifePLUS]

I do not. Hasn’t been an issue yet but it batteries rarely get drained

[@USA-GreedyMenOfNoIntegrity]

My 2020 Chevy express 2500 has a 110A alternator. The max current draw recommended is 83A or 75%. As long as you use a small DC-DC charger that pulls less than 40A and you have a switch to control it, a hall current sensor on alternator output, a meter to monitor the current draw on the alternator and maybe a thermistor temperature sensor to monitor alternator temperature…you should be fine. I keep under 83A and 90°C.

[@kenmoist]

What amp fuses did u use? And where did you get the second hot wire and ground for your switch up front? Went a little fast there

[@VanlifePLUS]

50 and 60amp fuses. Wires were just 12 garage from Princess Auto, same with the switch - any ‘ol store that sells them

[@shanemulligan3571]

I've got a van like this and would like to do something similar. How is it working out so far? Especially that positive connection under the driver seat. that seems like it could make things easier

[@VanlifePLUS]

So far so good, haven’t had any issues yet and yes, it was a lot easier than running wire from the engine bay

[@Moola48]

That seemed like quite the task, but looks like it worked out well. How have the batteries been holding up now? Now that it is almost one month later...

[@VanlifePLUS]

So far so good. They seem strong and are capable of everything I have thrown at them so far - which hasn’t been much yet. I will really need to install a monitor soon so I can know their exact levels better

[@jussikankinen9409]

Does it over charge starting battery if its full

[@jackieluckyangel5610]

🍀🥰

[@loko7051]

Do you have any kind of schematic for how you installed the switch for the charger? Or can you refer me to the site you were looking at for that? Thanks!

[@VanlifePLUS]

Sorry I don’t have anything like that on hand! You should be able to find something online fairly quickly. That being said it's not too hard - the red wire that comes from the fuse box (with the fuse tap) runs to the switch first (instead of directly to the DC to DC Charger) and then another red wire runs from the switch to the charger. My switch lights up when it is in the on position which means it has 3 connectors on the back. From the third connector I ran a wire down to the ground connection I used for the 6AWG cable that comes from the charger (the bolt below my seat) and that worked perfectly. If you have any other questions shoot me a message on Instagram @vanlifeplusmovies

[@FreeAgentChill]

Great video, Maybe I missed it in the video but does your Chevy Express have the standard 105a alternator? Im trying to decide between 40a and 60a charger.

[@VanlifePLUS]

OMG! Tingle and Shite Head? I'm dying....😂 love it No, you didn't miss it - no mention in the video. I'm not sure but I would assume it has the standard one, no reason to believe the previous owners would put in a high output one. I assume you are doing high capacity lithium in your build?

[@FreeAgentChill]

​@@VanlifePLUS Haha some one recognized it, Yes I will do Lithium batteries for these Canadian winters . Good to know I can use a 40a in this van! When the van is idling they say do not pull more than half the alternators rated amps.

[@aaronthedj12]

Princess Auto is your friend when doing any type of wiring

[@VanlifePLUS]

No kidding eh? Decent prices, frequent sales. I just hate that I get no reception in the store to look stuff up 😂 come prepared!

[@aaronthedj12]

@@VanlifePLUS that's true, it sometimes sucks for coverage . But that's why I walk around 5 times to go back up to the windows lol

[@aaronthedj12]

I could spend days in there

[@danteparra3020]

Thanks for that video, I recently done the same in my GMC, I know that cable come from the battery, but I wasn't sure will be safe for the van nor the DC to DC. Question, are you using the van often and hasn't been any issue?

[@VanlifePLUS]

Use it everyday 😂 I live in it full time. DC to DC charger gets used everyday too - no issues

[@USA-GreedyMenOfNoIntegrity]

There’s a 125A megafuse at engine compartment fuse box. That feeds the fuse box under driver seat. I would not put more than a 40A load on that B+ terminal under driver seat. I fused mine with a maxi fuse- 50A, within six inches of stud.

[@RonYason]

put a solar on top of the van roof \bro, 100watt should work perfect for your.

[@VanlifePLUS]

Yeah I’ll get there eventually lol. Probably sooner rather than later

[@RonYason]

@@VanlifePLUS I’ll be back there on Dec this year, we should talk about it if you want.

[@alanshaffer6724]

Hi Matt

[@dudedudeson546]

no the install begins at 9:10. almost ten minutes of talking. edit your videos kids

[@VanlifePLUS]

It’s a video log of my vanlife journey grandpa 😊 lol thanks for watching and commenting!

[@olejacobstalesen6558]

Haha! Converse, shorts, hoodie, white barn door van, that intro coulda been Chrome😅

[@VanlifePLUS]

True!!

[@beyouvanlife]

Congrats to your channel exploding. Love this video and so helpful as I am looking for a van to convert. Have a awesome day.