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DIY Relay Box
October 21, 2021
11:58 pm
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Sloguy
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Working on the install of the Winch Interrupt I needed a place to install a Relay.  I already had 2 Relays behind the dash for my Cameras and front Light bar so it was getting cluttered and I was planning on adding Rock Lights and A Pillar Lights also. I noticed that Jeff had zipped tied a couple of relays to the grill support bar which is a good idea but I needed 4 relays with the possibility of adding more and wanted better wire management.  I know I could go out and buy an S-POD or Switch Pro as I have for the JK but this is for the TJ which I am doing everything on a tighter budget.

I found this item for $30 on Amazon which came with all the connectors, relays and fuses. All you needed to do was wire it up yourself.

ref=ppx_yo2_dt_b_product_details

The Relay box does not have the best of instructions and does not have an integrated buss bar so you have to make some executive decisions on your own.  If you have the patience and a good array of crimpers, the box can be wired in a day or two. It took me a little longer as I color coded each relay and tried to get the wires as tight as I could which I had to redo a few of them.

Here is how I wired everything. All wires are loomed from the switches to the devices.

I spliced the radio power and put an inline fuse prior to connecting the wire to the switches.

From the switches I ran six 16 AWG CCA wires to the Relay box because that is what I had. I could have used 18 AWG as that would have been more than enough. I have 2 spare wires behind the dash for future connections.

The Relay box I used 14 AWG stranded Cu wire for all the connections. These were a little stiff but I preferred copper.

Input from the Switches to the Relay box I used a 6 pin Deutsch connector as the wires are smaller gauge.

Output from the Relay box to the Devices I used a 6 pin Weather Pack connector as it can handle up to 12 AWG wires and also so that I do not accidentally plug in the wrong connector.

The power to the relay is an 8 AWG Cu wire from the battery to a 50 amp circuit breaker then to a post on the Relay box. There was no buss bar and I was going to hang the Relay box so the bottom posts were not going to be used. Both posts are covered with rubber caps so positive and negative terminal ends are not exposed.

The negative connection is similar as I ran an 8 AWG Cu wire from the battery directly to a post on the Relay box.

To complete the Relay box I cut some 1/8 ABS plastic to protect the wires from behind.

Now all I have to do to add another device is install a switch (wires are already plumbed) and connect the device to an open pin on the Relay box output connector.

All told I spent about $60 for materials and increased my wiring skills so when I start the JK build it will go a lot smoother.

Hope this is of some interest to someone as I am by no means an expert on electrical and it is always best to have a professional do the work for you. (Disclaimer)

Enclosed are some pictures.

 

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October 22, 2021
8:02 am
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Jeff_R
Meadow Vista
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Sloguy said
I noticed that Jeff had zipped tied a couple of relays to the grill support bar which is a good idea but I needed 4 relays with the possibility of adding more and wanted better wire management. 

  

I think I was just insulted. All zip ties lives matter! Now that you have those lights we can include you on our next mall run.laughing  All kidding aside, looks great John!

October 22, 2021
8:31 am
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Jamie (K6NUB)
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That is a clean install John, you are a professional in my book!

K6NUB

October 22, 2021
12:01 pm
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JigglyJr
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Looks cleaner than anything I could wire. I hate electrical work.

nice write up as well! Keep it up!

Sean Rose
916-502-5082
1991 Toyota 4runner

October 22, 2021
4:56 pm
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Sloguy
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Jeff_R said

Sloguy said

I noticed that Jeff had zipped tied a couple of relays to the grill support bar which is a good idea but I needed 4 relays with the possibility of adding more and wanted better wire management. 

  

I think I was just insulted. All zip ties lives matter! Now that you have those lights we can include you on our next mall run.laughing  All kidding aside, looks great John!

  

Hey Jeff,

Consider yourself the inspiration haha.  I actually stole the idea from you but needed more relays. See you curbside soon! Only problem I didn't opt for the disco lights. I'm old and boring and just got plain white lights. Actually I'm so old I used to cruise Bird Cage and Sunrise Mall back in the day. We are the reason they put up those no U Turn signs after 9pm. Ahh the old days.

 

*No zip ties were harmed in the installation of the Relay box

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