What are you running off of it? And, is "continuous" to mean 200A @ 100%dc, or an intermittent high-duty cycle load? Last, where are you putting it? In free air? Under carpet? In a channel under trim?

Heat is the enemy.

 

It needs to be able to sustain 200 amps for the winch up front but ideally it won't be used very long and 200 is my cut off because I have it fused for 200 amps, theoretically should never pull more then 175 amps and its mixed, under carpet and open air zip tied to trim

 

I suppose my real question is a 200 amp fuse safe for 2 AWG wire over 15-20 feet fused both ends

 

That's a very good point. I guess it's time to pull the rest of my carpet. I have everything pulled behind my front seats.

 

Okay so I bought everything I need. The audio wire was crap so I went to the welding shop and picked up 1awg. I have created a diagram to show how I'm planning on wiring this up. In effect it is similar to a standard solenoid system but instead of a solenoid I just have the manual switch. So I wont have the automatic isolation feature but I will still have the ability to deselect one battery when and if I need it then just select the other to self jump start. The switch will be like I said before a 4 position switch off/bat1/bat2/both. The switch is rated for 300 amps continuous and 1000 amps peak. Does anyone see any problems with this? It seems to simple to work???

Or option 2 would be to just have battery 1 hooked up all the time with no switch, and battery 2 switched for emergencies and charging? This second option would prevent me/passenger from turning the switch to the off/bat2 position while running.

 

I'm wanting to do the same with my rig. Hope you don't mind me using your plans? After your marine switch what is that block? On the draw up.

 

As part of another set of mods that block will be a power distribution center. It will house all of my relays for lights/fan over ride/ compressor controls/etc. I will have an Anderson connection there to hook a set of custom jumpers to. I actually hope to run one up to the front and back. This way I can jump/weld/supply power from the front or rear of the vehicle.

 

Sounds like a lot to do. Also sounds like exactly what I have been wanting to do. Just haven't had the time/money to go through with it.

 

I agree, I have had so many problems with halfa$$ wiring and its just time to do it all right. I still can't decide which diagram I want to go with. Also I'm not sure if thst setup will cause a fluctuation in voltages. I was thinking about installing a capacitor next to my wiring box to take some of the fluctuations off with that long of battery cables.