Jim Thomas has been very helpful to us in the past, supplying wiring advice and a 'mini starter' to replace the GM starter that has hot start issues. We are currently working with Jim to completely rewire the main Barth circuits involving the alternator, starter, house and chassis batteries, generator, and substituting a 'battery separator' for the factory isolator. We also will be replacing the Autozone alternator for one remanufactured by Smith Auto Electric with all U.S. made components and their own technicians. When we finish, will provide a wiring diagram. One of the big changes will be to replace the "GM Magnetic Switch" by using the battery separator.
More later.
Jim and Tere

Sounds like a great idea! A wiring diagram would be sooo nice. Like you, I'm planning a major rewire of my heavy primary circuits.

I'm also looking a quality replacement alternator (and as of Monday, a distributor.) The replacement stuff I'm getting seems to be low quality.

A mini starter would be nice.

Steve, Smith Auto Electric in Yakima, Washington is absolutely first class. The owner, Jim Thomas, is a first rate guy and very knowledgeable. Their number is 509 453 8275 or toll free 800 822 0819. We bought a replacement starter from them and it completely solved all the 'hot start' problems we were having. They use no 'junk' parts. Define that anyway you want and you'll be right.
Jim

Good advice, Jim. I'm sick of "replacing the replacements." I'm going to call them for a good alternator, maybe starter, too.

I removed the diode isolator from the engine charging system.



This allowed me to remove several feet of heavy wire also. The previous system brought the alternator output forward to the isolator mounted above the radiator on the firewall. The return wires run back to the harness near the alternator. Bypassing the isolator allowed a direct connection from the alternator to the harness.

I installed a solenoid relay between the battery sets to allow cross charging when needed. The relay is wired to the switch on the instrument panel.



Fog light R&R is next...