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Dan and Kika install a new lithium battery bank in the cockpit locker and under the companionway of their boat, replacing an older system with one that provides four times the capacity at the same weight.21:06 To organize the installation, they 3D-print custom caps out of glass-reinforced nylon to hold fuse blocks and manage battery management system (BMS) cables.2:54 These caps feature threaded inserts and clips to ensure symmetrical wiring and consistent electrical resistance across the bank.3:24 The batteries include integrated bumpers that maintain a one-centimeter air gap between units for ventilation, eliminating the need for external spacers.22:28 The crew secures each battery using stainless steel mounting brackets bolted to the battery box floor.8:34 They also drill and epoxy drain holes in the corners of the battery boxes to prevent water accumulation, a recurring issue with their previous setup.7:20 The project concludes with the batteries and fuses in place, awaiting the final installation of a central bus bar system.18:43

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