BlueXJ - Hope I can answer everything
1) Did you have to cut the fenderwell to fit the box for the yellow top Optima?
Nope not at all.. No cutting anywhere. I recall relocating the PCM, but I think that was to make room for my ARB compressor. I don't believe it was needed for the battery.
2) Is that a Rustys airtube?
You have a sharp eye
, 100% correct.
3) Where did you find the labels for your cables?
I think at the time they also came from WranglerNW. But I've seen them on serveral electrical wiring retailer sites.
4)Where did you attach the positive cable from your isolator to the PDC at? (pic would help)
Good eye again. I believe the OE wire to the PDC was 10 gauge. It's entrance to the PDC is in the front of the box. I recall some minor challenges with this, but I believe it was a straight replacement to the OE mounting point. I'll try to remember to look tonight to verfiy this.
5) Do you have any issues with mismatched batteries? Red/Yellow optimas
Nope, I always keep the battery manager off the 'red' (combined) setting unless I truly need both batteries. This keeps both batteries separated all the time, so they don't compete to equalize, etc.
The only down side I've seen with this system, is there isn't an option to solely use the second battery. Since the second always feeds through the primary, you can never get a feel for the condition of the second battery. As a result, the second battery could die (and has) and you wouldn't know it until you go to use it. I just connect the secondary to a battery charger that shows voltage rates a few times a year to get a rough idea of the condition.
Hope this helps,