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AAL PowerPack Rack - Install and Thoughts

OEB0122

Badlands
Member
First Name
Bryan
Joined
Oct 18, 2025
Threads
2
Messages
13
Reaction score
6
Location
Georgia
Vehicle(s)
2025 Badlands SAS Bronco
Your Bronco Model
Badlands
When I initially saw the AAL PowerPack rack, thought it was a great idea! I knew I wanted to add a two-battery system in my rig; but this is the smallest space I have worked with.....so I was trying to come up with a space and battery configuration that would work for me. Then bam! AAL engineered a way to use the typically "dead space" under the shelf.

Initially received the order, and learned that AAL had mistakenly shipped the support brackets for the 100ah battery (I purchased the 150ah battery); so I had to wait a couple of weeks for them to fabricate, powder coat, and ship the correct support structures. Once I started assembly, my first pause for concern happened. This is a pretty heavy battery (~45lbs). Did I want it that high in the cargo area? More importantly, were the 18 little bolts supplied to support it going to hold when traversing through rough country.....? I almost decided to mount the battery lower on top of my drawer (topped with 3/4 birch plywood); then put an extruded aluminum frame/shelf around and over it for my fridge and storage solutions. Then, I decided since I am not an engineer, and there were probably smarter people than me involved in the design, I moved forward with installing just as it was designed. (Now....I wish I would have gone the route of installing on top of my drawer. Primarily because I could have gotten a cleaner install with wiring. Not that my finished product is bad, but could have been better. Also, as I will note below, I would have gone with a different charging system.)

Notes for anyone potentially interested in this sytem:
- The KC Energy battery BMS/App are VERY good. No real need to go with a robust smart shunt or manager system, as the app for the battery gives just about all of the info you would want/need organically. I went with the Redarc BDDC Alpha 50 charger, and the Redarc Smart Battery Monitor (later). After a full week of use camping, I do not open the Redarc app at all, unless I want to change settings.
- The AAL shelf's holes for the airline style track fittings are the perfect size for a 19mm push-button style switch. As you can see, I used 2 of them, as I have both my fridge and Starlink on switches.
- I like the Redarc BCDC 50 - easy to install, easy to configure, etc. However, I wish I would have gone with a system that provided an opportunity to use AC (shore power) charging. I would have liked having that option when wanting to top off at the house, staying at improved campgrounds, etc. Once I committed to installing all of the components on the under side of the shelf, I moved forward with the BCDC 50 - if doing again, would have gone with something different.

The full system has been installed for a week, and I went out for a 3-night trip over the holiday weekend.....everything worked flawlessly. Fridge stayed cold, Starlink had good power the whole time. So, all in all, a success.

Ford Bronco AAL PowerPack Rack - Install and Thoughts On Bench


Ford Bronco AAL PowerPack Rack - Install and Thoughts KC Energy A


Ford Bronco AAL PowerPack Rack - Install and Thoughts Install


Ford Bronco AAL PowerPack Rack - Install and Thoughts Install 2


Ford Bronco AAL PowerPack Rack - Install and Thoughts Install 3


Ford Bronco AAL PowerPack Rack - Install and Thoughts Install 4


Ford Bronco AAL PowerPack Rack - Install and Thoughts Complet
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