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Old 05-07-2010, 12:49 AM   #1 (permalink)
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Aux Switch / Fuse Box Information

Here's the deal, I am redoing alot of the previous mods in the FJ to make them up to my standard. I previously used the Blue Sea fuse box and external relays to run my auxiliary system. It works fine but I was not happy with the location or the wiring nightmare if something went wrong.

Goals: 10 total Switches, fuse box/relay box integrated into one box, wiring harness with connectable ends isolated from factory wiring, wiring colored for future trouble shooting, Must be located in the engine bay with easy access must look factory. Not spend a but load of money. Waterproof. Negative Circuit.

Now the install is off for a bit but since I am in the sandbox but wanted to share what information that I have so far. This will be a sort of work in progress until I can get the actual install done and fill in some of the gaps that I have. Be patient doing this with what little free time I have now. Stay tuned.

Changes will be reflected below to decision on circuit read post below
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Old 05-07-2010, 12:50 AM   #2 (permalink)
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Re: Aux Switch / Fuse Box Information

Navigation hint: pictures might end up telling you where these are from.

Parts Required:


Switch Panel:
Very Generous member on this board.


Switches:


6 - Carling Contura Rocker Switch (SPST 12V 20Amp W/ Lamp) $4.37


6- Black Contura II Actuators Amber Lens $.68
Though I may change up colors. But amber is the stock color.


6 - 8 position connector $.59
- Terminal Metri-Pak 630 20ga $.13

There are depending on how it is wired with 6 switches 12-13 wires. Again your mileage can vary as mine may when I get here and decide how to wire up the switches. The goal is well see above!


2 - 16 Circuit MX150 Connector Male $2.89
- Terminal male connector MX150 $.13


2 - 16 Circuit Connector Female $3.13
- Terminal female connector MX150 $.13

These are all the parts required for the switches besides wire. Labeling will be done with either the moduk labels or custom printed ones.

EX:


-------------------------

Relay / Fuse Box


Bussman mini fuse and micro relay Bussed $24.549

50 -- Terminal Metri-Pack 280 14-16GA $.10
50 -- Terminal Meti-Pack 280 20-22GA $.09
100 -- Packard Cable Seal Red #15324983 $.06
100 -- Packard Cavity Plug Green # 12010300 $.06
(Different terminal sizes to 1- 20 gauge from the switches 2- to go from relays for power requirements.)


12 - 35A 12v SDPST Resistor Relay ISO 280 $2.88
15 - Mini Fuse 30 Amp $.10
15 - Mini Fuse 2 Amp $.10

The 16 circuit connector will be used before the box so i can remove fuse box if needed. You of course will need a crimper that will work with above connectors. I am still working on wiring been looking at:

Relay from the battery/ignition.
Still looking for a fuse/relay to handle this probably a 50Amp relay.

Wiring:

Metra Harness 70-8117 Amplifier Relocation Harness 17 feet $25.95
My own power 10 Gauge from the battery and 16 gauge to the accessories (Should be able to handle 24 amps at 7 feet or 288 watts per terminal. The max of each block is 60 Amps / 720 watts at a time in each fuse block running continuously.

Metra harness used so all the circuits can be color coded in the wiring harness. I will wrap the harness to protect it and diagram it for electrical troubleshooting. The fuse boxes are water proof with all the connectors attached to be mounted by the spare battery.

This is what I have so far suggestions are welcome and I will add to this thread as I am able.

Last edited by redfernsoljah; 05-07-2010 at 01:13 AM. Reason: Added Parts.
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Old 05-07-2010, 12:51 AM   #3 (permalink)
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Re: Aux Switch / Fuse Box Information

Misc pictures of parts and crimp connectors.

Bussman fuse/ relay box totally waterproof up to 5 relays 10 fuses.


<<Note: This is not the Bussed Version just an example>>
ISO 280 end crimped


Micro relays
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Old 05-07-2010, 01:15 AM   #4 (permalink)
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Re: Aux Switch / Fuse Box Information

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Old 05-07-2010, 01:44 AM   #5 (permalink)
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Re: Aux Switch / Fuse Box Information

dmanit..its like a stip show...get all workd up, then stop....lol..looking foreward to it..good start
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Old 05-07-2010, 06:03 AM   #6 (permalink)
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Re: Aux Switch / Fuse Box Information

LOL, cant help it I have missions to run. My free time is pretty limited sometimes.
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Old 05-07-2010, 10:25 AM   #7 (permalink)
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Re: Aux Switch / Fuse Box Information

Here is a little chart that I made when deciding on you wiring needs and Gauge depending on the number of amps of an item. Remember to choose an adequately gauged wire that the circuit will carry and to fuse and relay appropriately for that accessory.



Even more to come...
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Old 05-07-2010, 10:36 AM   #8 (permalink)
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Re: Aux Switch / Fuse Box Information

Negative Circuit:
A relay can be wired so that it will operate when a ground connection is made or broken. The opposite of a positive circuit. If the switch is a significant distance from the relay the 12 volt wire also has to run that length. If this wire hit ground it will short circuit and blow a fuse. Hard to diagnose where. When using the ground connection the worst that could happen is that it will actuate the relay turning on the accessory. Making it much easier to find the short circuit. A plus when in the field. With this circuit isolated from the factory wiring and the starting battery, I feel that this is the best route to go. Though it doe include a few more parts, yet overall is much safer.

Negative Circuit Diagram


Positive to a Negative Trigger Needed from ACC or Ignition.
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