My 2dr Sasquatch project for 200Ah off grid power vs prepackaged.

[Deleted member 72780]

I wasnt trilled with proprietary parts and wanted modular/repairable design. Final will be a sort of link and go system to protect it, ie one at a time fridge, compressor in tail gate, lights etc

Part 1: Project Description
The objective of this project is to install a 200Ah Lithium (LiFePO4) house bank into the internal rear floor cubby of the Bronco. This build utilizes a Split-Architecture strategy to optimize energy density and vehicle balance:

• Internal Energy Zone (Trunk Cubby): The house bank is housed inside the cabin to protect the cells from extreme engine heat and freezing temperatures. Placing the batteries here allows them to benefit from the vehicle’s HVAC, ensuring an optimal environment for LiFePO4 chemistry.
• The Muscle Zone (Engine Bay): High-current winching remains connected to the factory AGM starter battery. This ensures the winch’s 400A+ draw does not encounter the BMS (Battery Management System) bottleneck of the lithium bank.
• The Power Hub: A Redarc BCDC1250D DC-DC charger, mounted on a Genesis Gen 3 Lid, acts as the central logic gate. It ensures the alternator charges the rear bank efficiently while keeping the house loads completely isolated from your starter battery.

Part 2: Weighted Importance & Comparison

This matrix applies a % Importance Weighting to prioritize safety and capacity. The DIY configuration offers a significantly lower cost per usable Amp Hour.

Metric	% Weight	DIY 200Ah (Internal)	Score	Genesis Power Hub Kit	Score
Redundancy/Safety	20%	Triple-Layer: Starter + House + NOCO	10	Dual-Layer: Starter + Aux AGM	8
Winching Power	20%	Direct AGM: No BMS Bottleneck	10	Direct AGM: Parallel Solenoid	10
Energy Capacity	20%	200Ah Lithium Reserve	10	~110Ah Total (AGM)	3
Cost per Ah (Usable)	10%	$8.17 / Ah (100% usable)	10	$27.29 / Ah (50% usable)	3
Weight Distribution	15%	Rear-Mount: Better SAS balance	9	Front-Heavy: 100lb nose load	4
Cold Performance	10%	Cabin-Temp: Protected by HVAC	9	Robust: AGM built for freezing	10
Installation Ease	5%	Science Project: Clean cable run	8	Bolt-on: Minimal engagement	10
TOTAL SCORE	100%		9.53		6.65

Part 3: Component Matrix (Optimized Cost)

Category	DIY Hybrid Setup (Rear)	DIY Cost	Genesis Full System (Front)	Genesis Cost
Hub / Distribution	Genesis Gen 3 Lid/Plate	$185.00	Genesis Power Hub	$799.00
House Bank	(2) LiTime 100Ah Xtra Mini	$480.00	(2) Odyssey ODP-AGM25	$702.00
Mounting / Mats	Monster Marine Aluminum Trays	$45.00	Integrated Dual Tray	(Included)
Tie-Downs	Heavy-Duty Battery Straps	(Included)	Stainless Steel Rods	(Included)
Charging Logic	Redarc BCDC1250D	$690.00	Integrated Smart Combiner	(Included)
Redundancy	NOCO Boost X GBX45	$125.00	Manual Boost Button	(Included)
Protection	Blue Sea MRBF Blocks	$65.00	300A Internal Fuse	(Included)
Wiring	Pre-cut 4 AWG Copper Kit	$44.00	2ga Pure Copper Harness	(Included)
TOTAL COST		~$1,634		~$1,501
Cost / Usable Ah		$8.17 / Ah		$27.29 / Ah

Part 4: Installation Strategy

1. Under-Hood Power Hub: Mount the Genesis Plate over the driver-side fuse box. Install the Redarc BCDC directly to this plate to minimize heat transfer to sensitive electronics. Connect the Redarc input to the starter battery (+) with a 60A inline fuse.
2. Internal Energy Conduit: Route the pre-cut 4 AWG copper through the firewall grommet and along the interior sills. The ~1.8% voltage drop at 50A ensures your Lithium bank reaches full charge efficiency from the Redarc unit.
3. Trunk Cubby Reserve: Fit the LiTime batteries in the floor cubby using Monster Marine Trays to provide a vibration-dampening pad and secure tie-down straps. Install the MRBF Terminal Fuses directly on the battery posts—this is critical to protect the 15-foot cable run.
4. Redundancy Bridge: Install a 12V-to-USB-C (60W) socket in the cubby to keep the NOCO GBX45 permanently topped off, ensuring your emergency jump pack is always ready.

Part 5: DIY Project Sourcing Links

• Batteries: (2) LiTime 100Ah Xtra Mini – $480.00
• Charging: Redarc BCDC1250D 50A DC-DC Charger – $690.00
• Hub Surface: Genesis Gen 3 Plate/Lid – $185.00
• Trays & Pads: Monster Marine Aluminum Battery Tray – $45.00
• Protection: Blue Sea MRBF Terminal Fuse Block – $65.00
• Redundancy: NOCO Boost X GBX45 1250A Jump Starter – $125.00
• Wiring: Pre-cut 4 AWG Copper Cable Kit – $44.00

Sponsored

 

[Techun]

As someone looking into these things also...how does this setup compare to a $600 2kw gas generator? Is "quiet" worth all of the other downsides?

 

[Squatch]

As someone looking into these things also...how does this setup compare to a $600 2kw gas generator? Is "quiet" worth all of the other downsides?

It's a personal choice if it's worth it to you, but if you've ever been out near the middle of nowhere, enjoying the serene, natural beauty and had an RV fire up the generator within a mile... I think it's worth it.

I used to hunt every year and it seemed like you could hear for miles while sitting on a ridge. When I go out to get away from things, "quiet" is one of the most important things next to food and water.

That said, I don't think I'll ever do this to my Bronco. I just don't use my Bronco that way. However, if I did, this looks exactly like what I'd want to do. I can't wait to see the finished project!

 

[jh3113]

So did you actually build this or just copy and paste from AI?

 

[swamp2]

What's the point of the scores? Seems only useful relative to another solution.

You might consider the robustness of the rear cargo box housing as it's plastic.

 

[Deleted member 72780]

I built it. Only tedious part is to lead 4 AWG wires to back cubby. It is way better if not in artic conditions as the two LItime batteries lay sideways and always 100% charged when driving. You can add solar.

If 2000 watts gnerator is worth it to you is decision. I compared to Genesis Offroad solutiuon where LI battieries would get fried in heat and cold year round so put in cubby.

I pulled out rear cargo pan and tied down on insulated rubber mat not mnetioned here, so good point. If in Idaho or Alaska etc may want AGM battery...

Rating is subjective so decide what features you like compared to Genesis offroad. I simply wanted it modular and you 3x power as Genesis for same money. Electronics project is rather simple but Au import from redarc is heart so dont skimp there. They sell grey makret imports not heat rated so be careful. I really have fo no need 2000 watts generator due to weight and noise nor need 2000 watts, I want lights(led) Fridge, etc so up to you.

I'll show pictures when all parts areive

 

[j_marinelli]

Awesome to see! I did a 100ah one in a home depot crate and currently working on another smaller one in an ammo box. Right now just have it set up as DC but great thing about building these is you can add/change components to fit your need.

On a side note, if you haven't bought the batteries yet, check out the cyclebatt mini's. Bluetooth feature was a pleasant surprise in being able to monitor and control features within the battery itself.

 

[Deleted member 72780]

Great to see. I have everything except dc-dc. I just bought form factor where two are on side with rubber mat with cubby tray pulled.

AI really makes it a buy once experience even if a simple project.

 

[Kevin Scarbel]

I wasnt trilled with proprietary parts and wanted modular/repairable design. Final will be a sort of link and go system to protect it, ie one at a time fridge, compressor in tail gate, lights etc

Part 1: Project Description
The objective of this project is to install a 200Ah Lithium (LiFePO4) house bank into the internal rear floor cubby of the Bronco. This build utilizes a Split-Architecture strategy to optimize energy density and vehicle balance:

• Internal Energy Zone (Trunk Cubby): The house bank is housed inside the cabin to protect the cells from extreme engine heat and freezing temperatures. Placing the batteries here allows them to benefit from the vehicle’s HVAC, ensuring an optimal environment for LiFePO4 chemistry.
• The Muscle Zone (Engine Bay): High-current winching remains connected to the factory AGM starter battery. This ensures the winch’s 400A+ draw does not encounter the BMS (Battery Management System) bottleneck of the lithium bank.
• The Power Hub: A Redarc BCDC1250D DC-DC charger, mounted on a Genesis Gen 3 Lid, acts as the central logic gate. It ensures the alternator charges the rear bank efficiently while keeping the house loads completely isolated from your starter battery.

Part 2: Weighted Importance & Comparison

This matrix applies a % Importance Weighting to prioritize safety and capacity. The DIY configuration offers a significantly lower cost per usable Amp Hour.

Metric	% Weight	DIY 200Ah (Internal)	Score	Genesis Power Hub Kit	Score
Redundancy/Safety	20%	Triple-Layer: Starter + House + NOCO	10	Dual-Layer: Starter + Aux AGM	8
Winching Power	20%	Direct AGM: No BMS Bottleneck	10	Direct AGM: Parallel Solenoid	10
Energy Capacity	20%	200Ah Lithium Reserve	10	~110Ah Total (AGM)	3
Cost per Ah (Usable)	10%	$8.17 / Ah (100% usable)	10	$27.29 / Ah (50% usable)	3
Weight Distribution	15%	Rear-Mount: Better SAS balance	9	Front-Heavy: 100lb nose load	4
Cold Performance	10%	Cabin-Temp: Protected by HVAC	9	Robust: AGM built for freezing	10
Installation Ease	5%	Science Project: Clean cable run	8	Bolt-on: Minimal engagement	10
TOTAL SCORE	100%		9.53		6.65

Part 3: Component Matrix (Optimized Cost)

Category	DIY Hybrid Setup (Rear)	DIY Cost	Genesis Full System (Front)	Genesis Cost
Hub / Distribution	Genesis Gen 3 Lid/Plate	$185.00	Genesis Power Hub	$799.00
House Bank	(2) LiTime 100Ah Xtra Mini	$480.00	(2) Odyssey ODP-AGM25	$702.00
Mounting / Mats	Monster Marine Aluminum Trays	$45.00	Integrated Dual Tray	(Included)
Tie-Downs	Heavy-Duty Battery Straps	(Included)	Stainless Steel Rods	(Included)
Charging Logic	Redarc BCDC1250D	$690.00	Integrated Smart Combiner	(Included)
Redundancy	NOCO Boost X GBX45	$125.00	Manual Boost Button	(Included)
Protection	Blue Sea MRBF Blocks	$65.00	300A Internal Fuse	(Included)
Wiring	Pre-cut 4 AWG Copper Kit	$44.00	2ga Pure Copper Harness	(Included)
TOTAL COST		~$1,634		~$1,501
Cost / Usable Ah		$8.17 / Ah		$27.29 / Ah

Part 4: Installation Strategy

1. Under-Hood Power Hub: Mount the Genesis Plate over the driver-side fuse box. Install the Redarc BCDC directly to this plate to minimize heat transfer to sensitive electronics. Connect the Redarc input to the starter battery (+) with a 60A inline fuse.
2. Internal Energy Conduit: Route the pre-cut 4 AWG copper through the firewall grommet and along the interior sills. The ~1.8% voltage drop at 50A ensures your Lithium bank reaches full charge efficiency from the Redarc unit.
3. Trunk Cubby Reserve: Fit the LiTime batteries in the floor cubby using Monster Marine Trays to provide a vibration-dampening pad and secure tie-down straps. Install the MRBF Terminal Fuses directly on the battery posts—this is critical to protect the 15-foot cable run.
4. Redundancy Bridge: Install a 12V-to-USB-C (60W) socket in the cubby to keep the NOCO GBX45 permanently topped off, ensuring your emergency jump pack is always ready.

Part 5: DIY Project Sourcing Links

• Batteries: (2) LiTime 100Ah Xtra Mini – $480.00
• Charging: Redarc BCDC1250D 50A DC-DC Charger – $690.00
• Hub Surface: Genesis Gen 3 Plate/Lid – $185.00
• Trays & Pads: Monster Marine Aluminum Battery Tray – $45.00
• Protection: Blue Sea MRBF Terminal Fuse Block – $65.00
• Redundancy: NOCO Boost X GBX45 1250A Jump Starter – $125.00
• Wiring: Pre-cut 4 AWG Copper Cable Kit – $44.00

I personally would work around Dragonfly Energy's Battle Born batteries (a GC3 if I could) and Victron components (the industry best).

 

[telenerd]

What a nerd.

 

[Deleted member 72780]

Victron makes great lower cost product. It needs to be in dry cabin not mounted on plate on fuse box though.

I am afraid to look at battleborn prices for lithium batteries. Dragonfly if same company is getting defense contracts now!

One I picked lays on side and fits two in cubby with tray removed., secured down on rubber mat. You could pick victron to fit in cubby.

If you do that is should've 18ga wire strung as signal wire to cubby too

WHOLLY CR@P Battleborn is 650+ for standard 100 ah battery. This is insane unless a military contractor.

 

[TLO]

I personally would work around Dragonfly Energy's Battle Born batteries (a GC3 if I could) and Victron components (the industry best).

Battleborn batteries are overpriced, dangerous garbage... I'd avoid them. Ask Will Prouse

 

[TLO]

Would love to see you fit 2X 100ah cells in the trunk cubby...
Pics please

 

[JediMcMuffin]

Solid design, but personally I think thats an absurd amount of battery capacity. Just what are you planning to power? Some large RVs have similar capacity.

 

[Deleted member 72780]

The Setup:

• Fridge: Running 24/7 to keep food/drinks cold.
• Electric Blanket: Used for 8 hours each night (on a medium setting).
• Lights: 4 hours of evening illumination.
• Gadgets: Charging two phones and one tablet daily.

The Math:

1. Fridge: 20W * 48hrs= 960Whs
2. Electric Blanket: 60W * 16hrs (2 nights) = 960Whs
3. LED Lights: 10W * 8hrs(2 nights)} = 80Whs
4. Gadget Charging: ~200Wh total.

Total Consumption: ~2,200Wh

Two days. - Sincw project is 1500 and second battery is 250 ish I see no issue.

Sponsored