Saturday, Feb 28, 2015 at 14:59
Peter, What you have said is misleading.
The OP's vehicle is a Hilux. He has said.. "I've got the dual battery and the engle fridge running in the tray". He also said... "dual battery in the tray with dedicated positive and ground to chassis, uhf wired with dedicated positive and earth to chassis." When he says "chassis" he may
well mean 'body'.
The tray is not "spot welded" to the chassis. In fact the whole bodywork is bolted to the chassis.
Then there are body panels such as mudguards that are attached to the adjacent body by bolting, not welding. There is no deliberate electrical path provided in the bodywork.
There are numerous
places in current vehicles where there is no constructive electrical bonding and electrical resistance can and does develop. On top of that the steel body and chassis have significant electrical resistance.
My reference to "chassis return" was a generalisation to include chassis, body or any other path than an intentional copper cable for return of the load current.
I would be surprised if you were not aware of such problems as "earth loops" where the "grounded" ends in signal cables were at differing potentials introducing unintended current paths and interference in the signal. This is normally eliminated by astute grounding of shields and effective bonding of components to avoid IR voltdrops in the structure.
For many reasons, it is not good practice to employ body and chassis returns of significant currents.
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