I would protect the wire with nylon spiral-wrap insulation, or slip it
into some tough, abrasion-resistant tube wherever it is exposed to any
harshness or abrasion.

You would also want to make sure wire's insulation and protection are
fuel-resistant, in case the tank and related tubing and seals ever
leaks. However, most materials used for the job are likely to be so.

Your local hardware store, FLAPS or electronics store should have
something to do the job.

You may have to enlarge the holes the wire goes through. Also use
grommets so the holes don't slice through. Lots of vibration to deal
with.

Then you should not have to worry about wearing or cutting through the
insulation on the wire.
I'd be very nervous knowing I have the potential for a very
high-amperage wire short to ground right there on the gas tank, I'd use
the most abrasion-resistant material that I could reasonably get a hold
of.

For instance, I ran an 8ga. cable from my main battery, through the
battery-box vent (it's a Syncro), to the front of the van where it
supplies the small supernovas used in the headlights. You bet I used
copious amounts of nylon spiral-wrap to protect the insulation, and it
is on a circuit-breaker at the battery as well.

My 2mA worth,

Ron Antaki

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Spinoso, Tom
Sent: Thursday, June 03, 2004 8:47 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Aux Battery Wiring safe? - NEW TOPIC (I think)

Hi everyone...

I have just recently added an aux battery to my Carat.  I used a Sure
Power 1315 and an Optima yellow top battery with excellent results.
Actually I wired an inverter, smart charger and automatic shore power
transfer switch
(mouthful) as well.  It actually works great.  In order to connect the
two batteries together I had to drill some holes in the bottom of the
battery compartments behind each seat - the wire run is a straight shot.
I then "snaked" 4 gauge between each battery bay.  My concern is
where/how these wires are snaked underneath the van.  More specifically,
(while doing this my wife helped) and she realized the cable basically
lying on top or near the gas tank.  I was not up to removing the gas
tank to secure the wires - I would not know where to begin.  Do I have
anything to worry about?  I have studied various threads where this has
been done before, but this topic seems not to have been addressed.  I
would be interested in hearing from those who have done it and could
give an update on how the wires have survived...  Sorry for the long
post.  Thanks for any help.

"Chasin' Rainbows" - 91 Carat

Tom