2TR-FE 130 amp alternator + regulator upgrade for AGM batteries

Figured I'll give an update for others to learn from my experience...

So I did the change and installed the largest PAL fuse I could find that would fit the factory slot (wanted to keep it tidy), which was rated 140 AMP.
Seemed to work fine until it blew a week and half later (was a hot day using the AC I suspect may triggered but not sure).
I resolved to frankenstein-ing a 150 AMP fuse onto the PAL prongs and somehow bend to fit.
Has been working fine for the last month including a 1,300 Mile road trip I took last week.

Some related pics including the specs of longer bolt I needed for the third leg (Save the trip to the store!):



P.S. I added a thick wire all the way to the positive battery terminal but haven't done any beefing up of cable for the negative. Wasn't sure where/what exactly if any needed... Thoughts?

 

Well done!

 

At bare minimum I would upgrade the engine to chassis ground as it is the other half of the circuit for the alternator positive. The fact that you blew a 140 amp fuse with only a 130 amp output alternator means you are attempting to draw a lot of amperage. I'd suggest replacing all your main grounds and powers with larger gauge wire. You shouldn't be drawing that much amperage with what you have hooked up. I suspect a corroded or loose ground or power wire somewhere is causing a problem.