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Relay Panel
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AZRich
AZ Pinstriped
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Tue May 23, 2017 8:38 pm    Post subject: Relay Panel Reply with quote

So let me preface this by saying I'm not an electrician or IT specialist or anything even remotely close to a professional at wiring things, but I'm pretty proud of how this turned out. I wanted a centralized location for my relays and fuses for my various lights around the FJ and came up with this solution after watching several YouTube videos and seeing what other FJers and Jeepers were doing. It's basically my version of an SPOD but not nearly as sophisticated...but not nearly as expensive either. Everything shown here was less than $100 whereas an SPOD is about $400. It's located in the large empty area on the passenger side of the engine compartment where a second battery or air compressor could go. I used 1/4" thick ABS plastic as the platform and two black aluminum L brackets to mount it to the body. I haven't wired any lights or anything to it yet so there aren't any fuses, grounds or power wires going to this yet. My plan is to have a 4 gauge cable from the battery to a distribution block mounted on this board where it will split into 3 - 8 gauge cables, 1 for this blue sea fuse block and 2 for my stereo amplifiers. The grounds for the relays will go to one of the bolts that hold this board to the body panel.






My questions to AZFJ are:
Is this location ok? Do you see any potential issues with locating it here?
Does it look stupid or like it's wired incorrectly?
Anything I should do differently?

Thanks as always for the help!

Rich
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Jimbolio
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Joined: Oct 19, 2008
Posts: 11590
Location: Tucson

PostPosted: Wed May 24, 2017 7:17 am    Post subject: Re: Relay Panel Reply with quote

You might want to find a cover to keep water out

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AZRich
AZ Pinstriped
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Wed May 24, 2017 8:07 am    Post subject: Re: Relay Panel Reply with quote

Thanks, Jim, I did think of doing that, but couldn't find a box that was the size I needed. Also, I have relays in the engine compartment right now for all my lights and they are exposed to the elements and have been for several years. I haven't had any problems with them so far. I don't do any real water crossings in the FJ and that's the only time I can think where water could get that high into the engine bay. Spray from wet roads wouldn't be enough to affect this, would it?
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Jimbolio
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PostPosted: Wed May 24, 2017 9:13 am    Post subject: Re: Relay Panel Reply with quote

I was thinking that and dust too. But that would be impossible to keep out.
What are the measurements? Maybe an electronics project box might fit.

www.polycase.com/an-se...oChmHw_wcB

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AZRich
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Wed May 24, 2017 11:15 am    Post subject: Re: Relay Panel Reply with quote

I thought about those boxes too, just got tired of searching the interwebs for the right size. The board I'm using is 15"x7" and should only be a max of about 3" tall. I could reduce the length to a minimum of about 11.5" which is the distance between my mountain points. The width can't get much lower because the relays are each a little over 1" wide. But the box can't be more than about 7-3/8" wide to fit next to the air intake.
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azflycaster
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Joined: May 12, 2013
Posts: 2283
Location: Fountain Hills

PostPosted: Wed May 24, 2017 12:31 pm    Post subject: Re: Relay Panel Reply with quote

www.the-cover-store.co...oCt9Dw_wcB

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calichaos
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Joined: Feb 08, 2011
Posts: 1886

PostPosted: Wed May 24, 2017 2:07 pm    Post subject: Re: Relay Panel Reply with quote

perhaps

www.amazon.com/Disposa...B005DXN41G

or a bit tougher

www.amazon.com/Reusabl...B000RCHF40

or maybe a tad tougher
www.amazon.com/Silikom...B0087PRSBY


and 30 seconds with Google search "15 x 7 x 3" plastic box found this:

www.angela.com/hammond...-1573.aspx
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AZRich
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Wed May 24, 2017 2:51 pm    Post subject: Re: Relay Panel Reply with quote

Thanks, cali, we can always count on you for the perfect google search results! I'm not sure about the aluminum case, it looks like it's open on one side - so i would just place this on top of the board I made? Doesn't seem too watertight, but I like the way you're thinking!

I was also referred to the Eaton Bussmann relay/fuse block and that seems like a pretty good way to go too. I may end up switching to that setup. It's pretty reasonably priced and it's watertight. However, I would still probably use terminal strips to connect to the switches and I would need to protect those somehow.

www.waytekwire.com/ite...GE61AK10S5

www.waytekwire.com/ite...1-0A-RFRM/
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4GaugeSurprise
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Joined: Jul 16, 2013
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PostPosted: Wed May 24, 2017 3:03 pm    Post subject: Re: Relay Panel Reply with quote

a bussman style box with micro relays is the way to go. water and dust tight, everything contained in a very small space. all connections are color coded...
Not putting down the work you put into what you built, just suggesting options to look at if you decide to use that space for something else (like another battery to deal with whatever you need 4GA wire for).

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4GaugeSurprise
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PostPosted: Wed May 24, 2017 3:06 pm    Post subject: Re: Relay Panel Reply with quote

Here's the thread where I used a bussman box after thinking things through for a while.
azfj.org/index.php?nam...pic&t=9188

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AZRich
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Wed May 24, 2017 3:21 pm    Post subject: Re: Relay Panel Reply with quote

4GaugeSurprise wrote:
a bussman style box with micro relays is the way to go. water and dust tight, everything contained in a very small space. all connections are color coded...
Not putting down the work you put into what you built, just suggesting options to look at if you decide to use that space for something else (like another battery to deal with whatever you need 4GA wire for).

Yup, I think I'm definitely leaning this direction now. It was fun building what I did, but the bussmann seems like such a much more efficient use of space.

The 4 gauge wire is to power two stereo amplifiers and this bank of relays. I only wanted one connection to the battery and thought that wire size should be sufficient for the amp draw. It may be overkill, but that just gives me more capacity for adding other goodies in the future without adding another battery connection.

Do you have the ordering information for the one you used?
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4GaugeSurprise
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Joined: Jul 16, 2013
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PostPosted: Wed May 24, 2017 8:27 pm    Post subject: Re: Relay Panel Reply with quote

The guy that built mine (with a fusable link and bracket) seems to have called it quits as of monday (no shit).
forum.ih8mud.com/threa...02/page-10

maybe you can coax one out of him, maybe not. But there are a few other places to get the same thing, or you can build one yourself. I know Wikid had the larger version that held 10 relays I think, not sure if he went to the same guy, search for his thread about the bussman.

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AZRich
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Wed May 24, 2017 9:09 pm    Post subject: Re: Relay Panel Reply with quote

Damn, oh well. I did find a site online where I can buy one and saw the 10 relay model there too. I just can't tell if I need to buy some kind of small connector for the wires to plug into the box or if they come with it. Also looks like there are some plugs to fill the unused holes that I may need to buy. I know I need to get the micro relays and fuses separately, just wondering about the other stuff. Here's the site I found:

www.waytekwire.com/ite...Mini-Fuse/

Clicking on the data sheet shows several options for accessories and I'm not sure which ones, if any, that I would need.
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4GaugeSurprise
Obstacle Crusher
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Joined: Jul 16, 2013
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PostPosted: Wed May 24, 2017 11:03 pm    Post subject: Re: Relay Panel Reply with quote

I don't suggest trying to build your own unless you REALLY want to, and plan on building quite a few more to sell. You'll need all the male and female connectors, the correct crimpers, all the plugs and sleeves for the holes (including the ones with wires in them) and a spool of GXL wire in each color. Basically it will be 10x more expensive to do a one-off.
What you are linked to is simply the skeleton to build the system, like buying a bare circuit board. There is a ton of little stuff that you'll need to buy in bulk and a ton of work to make it come together.

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AZRich
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Joined: Feb 10, 2010
Posts: 177
Location: Ahwatukee

PostPosted: Thu May 25, 2017 6:43 pm    Post subject: Re: Relay Panel Reply with quote

I was actually directed to an eBay listing by someone on Facebook with one of the 5 relay setups all wired up and ready to go for $130. That will probably be the route I go. Here's the link I was sent in case anybody else is interested:

m.ebay.com/itm/Univers...Ciid%253A2
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