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Thread: bluesman2a : Project: Electrical Overkill

  1. #1
    Join Date
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    Default bluesman2a : Project: Electrical Overkill

    Project: Electrical Overkill
    Post by bluesman2a on Aug 19, 2006, 1:17pm

    OK, I'll admit it, I'm an electrical junkie. I like a well designed system, and I've never found one kit that had it all, so I put together my own. Over the next couple of days I'll post up some electrical resources, but let's start with components:

    1) Wire -- Good quality battery cable, I use either 2 or 4 Ga. welding cable, it's finer stranded, you can route it easier than crap you find in auto parts stores, and it's better quality. Good deals on rolls of colored wire can be had from Del CIty. Try to color code your stuff.

    2) Connectors -- At the moment I'm currently using a lot of moulded/sealed male/female spade connectors, we'll see how they hold up. May change over to the weather-pak or deutsche connectors depending on how these hold up.

    3) Circuit protection -- There are a couple of things I really like here.
    A) resettable hi-amp breakers: these are great for basic system-wide protection (near the battery) and make a great way to shut things down for maintenance or long storage. Available in surface mount or if you cut a hole to mount in the dash, panel mount. Think of it like a VERY high capacity switch. Range from 150 amps down to 60. Commonly available in marine supply, are weatherproof, but cheapest place I have found these is Del City:
    http://www.delcity.net/delcity/servl...=193073&page=1


    B) Mini-breakers: same idea just slightly smaller, in the 30-50 amp range.
    http://www.delcity.net/delcity/servl...=742604&page=1


    C) Fuse/distribution panels: these are VERY cool. Takes a lot of wire and makes it very clean. Essentially this is a good way to pre-wire stuff for making additional accessories a SNAP to add in.
    http://www.westmarine.com/webapp/wcs/sto....productId=91545


    D) Hot Rod panels: These make for a more refined under dash look. They also come pre-wired for things like flashers and horn relay.
    http://www.centechwire.com/catalog/panels/index.html

    4) Switching: Normal switches can't handle the loads we put on them. To that end you need to have controls. We do this through the use of Relays and Solenoids. Both are essentially switches that we use to control LARGE loads. For example, putting your headlights on relays will not only give you brighter lights (direct feed), but it will increase the longevity of the switch in most applications.

    A) Relays: I like these from Del City, they're cheap, they fasten together, come with a nice pre-made harness, and they are easy to mount.
    http://www.delcity.net/delcity/servl...d=72563&page=1


    B) Solenoids: There are continuous duty solenoids (made to stay on all the time) or intermittent solenoids (like a starter solenoid). The two are NOT interchangeable. On my system I added two continuous duty 85 amp solenoids so I could have bountiful amounts of KEYED power (i.e. on when the ignition is on).
    http://www.delcity.net/delcity/servl...=790161&page=1


    5) Doo-dads and -Jaws: Cool and useful stuff.

    A) Cable Lugs: I use either coper or tinned. Get them here cheap.
    http://www.delcity.net/delcity/servl...tid=102&page=1


    B) Zip tie mounts: Pop a hole and you have an easy way to secure/route something with a zip-tie. I love these things and use them by the hundreds.
    http://www.delcity.net/delcity/servl...tid=127&page=1


    C) Cable end covers: I hate exposed hot wires, use these boots to good effect.
    http://www.bluesea.com/product.asp?P...62&l1=7462&l2=


    D) Bus Bars: Clean up your wiring and make it look neat.
    http://www.westmarine.com/webapp/wcs/sto....10001/119/118/9


    E) Bulkhead pass-throughs: Pass through big cables with easy disconnect.
    http://www.westmarine.com/webapp/wcs/sto....10001/119/118/9

  2. #2
    Join Date
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    Default bluesman2a :

    Re: Project: Electrical Overkill
    Post by bluesman2a on Aug 19, 2006, 1:18pm

    As I go through this, I'll try to get some pics of how all this stuff hangs together actually installed IN the truck.

  3. #3
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    northern Arizona
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    Default compexp :

    Re: Project: Electrical Overkill
    Post by compexp on Aug 19, 2006, 2:36pm

    nice info

  4. #4

    Default tacomainoh :

    Re: Project: Electrical Overkill
    Post by tacomainoh on Aug 19, 2006, 3:23pm

    great post, and good ideas!

  5. #5
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    North Central Wisconsin
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    Default brute4c :

    Re: Project: Electrical Overkill
    Post by brute4c on Aug 19, 2006, 4:17pm

    FANTASTIC STUFF!!!!!

    I have one of those first breakers....120 amp rated in 24V...came off a european several ton truck....got it free at a junkyard cause they thought I was nuts for wanting it.

    I put a large box in the bed for my batteries and strapts, tools etc. Those through fire wall connectors are perfect for that....i put 2 sets in so I have both 24 and 12 volt taps....ran "00" battery cables custom made from welding cable....the more the merrier in sub zero weather....

  6. #6
    Join Date
    Dec 2006
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    Auburn, AL
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    Default snuffy :

    Re: Project: Electrical Overkill
    Post by snuffy on Aug 19, 2006, 9:04pm

    Nice post!

    Any experience with the military breakers - newer style?

  7. #7

    Default k8icu :

    Re: Project: Electrical Overkill
    Post by k8icu on Sept 8, 2006, 9:52pm

    I think the mill system works very well. Can't beat a stock harness. But that just MHO.

  8. #8
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    Default bluesman2a :

    Re: Project: Electrical Overkill
    Post by bluesman2a on Sept 9, 2006, 6:15am


    Quote:
    I think the mill system works very well. Can't beat a stock harness. But that just MHO.


    I think for the stock trucks it's elegant in it's simplicity. It works and it's built well. Unfortunately mine was hacked apart years before I set eyes on my truck, and it wasn't worth it for me to try to maintain the authenticity (nothing else on the truck is original at this point except the body/frame )

    And of course, like the rest of the truck, this IS about the OVERKILL.

  9. #9
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    Default compexp :

    Re: Project: Electrical Overkill
    Post by compexp on Sept 9, 2006, 9:18am

    I would be interested in your full wiring diagram if you have one drawn up. Electrical's my weak point, as I'm sure it is for a lot of other guys.

  10. #10

    Default davea :

    Re: Project: Electrical Overkill
    Post by davea on Sept 9, 2006, 1:06pm

    That's not a bad idea. We have a stock wiring diagram filed here, why not an easy to replicate harness for the modified trucks? Most of them are going to be using the same basic components (H.E.I. dist., Delco alt, etc.), it would be nice to have a shopping list of required circuit breakers, fuses, wire gauge, and such before starting the job.

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