- Are there specific benefits to retaining 24v,
Yes:
- It's a more powerful starting system, better able to turn over a diesel engine, especial when things are a bit on the weak side.
- Since it's 24v, you don't need as much copper in your battery to starter wiring. If you go 12v, you should upgrade all your battery cables.
- If it's stock CUCV, you can troubleshoot using the TMs (available free here on the site) and with help from Steel Soldiers members. If you convert to 12v, you are on your own.
Probably the only real downside of the 24v system is that you can't get a jump from every Tom, Dick, and Harry on the street. (Well, you can, but it's not nearly as simple. You basically have to charge both batteries in turn, then start the beast.)
- assuming that I carefully solder / seal everything and do a good job?
Solder is
not better than properly done crimps. There are good reasons that solder is
permitted in marine applications, and crimp connections are
preferred. Same for many avionics and military applications.
Do not use solder in the starter circuit.
- Is there any way to eliminate the starter relay if you go 12v? I'm assuming the circuit for the starter switch is not beefy enough to engage the solenoid directly. Is there another option?
Nope. You still need a starter relay. It's not a problem. The Doghead Relay mod is insurance against a poorly speced part, not a cure for an inherently bad design. There's not a thing wrong with the design. Every vehicle I own has a starter relay to drive the solenoid. I doubt there are many cars that do otherwise. A starter solenoid draws a good chunk of current. You'd be crazy to push that much current through the key switch.
THAT would be a lousy design.
- As suggested by the subject line, can anything in addition to one alternator and the glow plug relays be removed?
Glow plug relay is needed, whether it's 12v or 24v. Same one works fine. If you are going to run a winch and ham, you probably need to keep both alts and batteries, or at least upgrade the stock ones. I am no expert on diesels, especiallly what's out there now, but all the ones I've seen have two batteries in parallel for starting.
- I will definitely be adding a winch and a HAM radio. How does that factor in to the debate?
It doesn't. There's plenty of 12v available for your 12v accessories. Well, a 24v winch is going to be lighter than a 12v, for the same amount of pull. Smaller windings. More efficient. But, they may be a bit more pricey. And of course, like the battery wiring, you can use smaller wire for a 24v system than a 12v system of the same power.
Sorry of these are stupid questions or have been covered 1000x already.
Not stupid at all!
But yeah, they have been covered.
I'm really trying hard to get up to speed on this vehicle and the best ways to make it reliable. Thanks.
The stock system is quite reliable. You read about a lot of problems because these are 30 year old vehicles.
