UPDATE - 9-2-14 -Custom power distribution/relay panel mounted in the glove box - Ram 2500 -

[firefighter_2000]

This is all still a work in progress:


Built this panel for my truck. Working on several custom built parts/accessories for it. This is the current project. It will be mounted in the glove box.


The coiled cord will head up to the switchbox and includes power/ground wires as well as wires to trigger each relay.


The power will be sent to each accessory via the terminal block on the top right.




Here it is mounted in the glove box.






Added a circuit breaker in the bottom for my air compressor.




The wires coming in through the bottom through a hole I cut. Everything comes in/goes out thru there.




Main power is supplied to the panel starting here, through a 60 amp relay, then through a heavy duty Eaton Cutler solenoid. It will be triggered from an ignition circuit inside the under hood fuse panel.




For the trigger... Drill a small hole here:




Then put the trigger wire from the solenoid in through there.




Made this custom "pin" to insert into the open ignition hot cavity of F90/91 (rear power outlet). I've got the fuse in the always hot location so the rear power outlet stays hot for a charger. I actually squared off an ATM fuse leg, then soldered it into a solder & shrink connector. It easily plugs right in. Triggers the solenoid perfectly each time.




Custom pin in place. The top of the pic is towards the front of the truck.




This is the plug under the truck where all wires come in. Passenger side under the carpet. All sealed up with silicone. The right side is towards the front of the truck.

 

[unlisted]

Very nice.

 

[Surgicalcric]

Looks good, and clean

 

[Steve0625]

Nicely done! Is the base material for the relay/distribution panel fabricated out of ABS stock? And what thickness did you use?

 

[firefighter_2000]

Yes. Bought a scrap sheet of the ABS plastic with the "hair cell" pattern on one side, from a local vendor. They even cut off two of the 5"x15" pieces for me and I kept the rest. I believe it's the 3/16" thickness. Was initially going to try 1/8 but they didn't have any scrap. The 3/16" ended up working perfectly.

 

[firefighter_2000]

Updated.

 

[paff2]

 Did you make your own wiring harness or buy it? 

 

[firefighter_2000]

Which harness? The coiled cord that will go to the switch box is from a lightbar that was cut short, and I just covered it with poly expandable sleeving. Everything else I made custom myself.


Craig

 

[txff914]

For your fuse tap it might be better to go with a mini fuse tap it will work with those Ford low pro fuses. The way you have it now might easily break off, just by looking at it.

 

[firebuff17]

Looks very nice!!


What are you using for switches? Where/how are you mounting the switches or switchbox?


I might be jumping the gun on these questions but I am interested.

 

[paff2]

Which harness? The coiled cord that will go to the switch box is from a lightbar that was cut short, and I just covered it with poly expandable sleeving. Everything else I made custom myself.


Craig

 Yeah I was referring to the coiled cord. Thanks 

 

[firefighter_2000]

For your fuse tap it might be better to go with a mini fuse tap it will work with those Ford low pro fuses. The way you have it now might easily break off, just by looking at it.

Very interesting idea... I'm not familiar with the fuse taps. Could you explain/show how those work?
Thanks!

Looks very nice!!


What are you using for switches? Where/how are you mounting the switches or switchbox?


I might be jumping the gun on these questions but I am interested.

I found an article in 4-wheeler magazine dealing with this and it's been the only good, clean solution I've found. The box is being custom built by a metal fab company in CA. The only difference in mine is it will have rocker switches instead of toggles and labels. I plan on using the Eaton NGR switches. I'll post pics of that as soon as I get that up & going.

 

[firebuff17]

Oh that's cool. Can't wait to see the installed pics. And of course final project completed

 

[fordtruck661]

Very interesting idea... I'm not familiar with the fuse taps. Could you explain/show how those work?


Thanks!

I believe this is what he is talking about.....Its what I used and it works very well

http://www.autozone.com/autozone/accessories/Cooper-Bussmann-ATM-fuse-tap/_/N-25gq?itemIdentifier=32416_0_0_

 

[firefighter_2000]

The link is not showing up correctly on my mobile device. Is it the "add a fuse" style with a wire coming from it? I've used them in the past with poor luck. Even when triggering a relay. They must have more resistance than normal, because they would heat up and get soft. Time will tell how this one works out.