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Ideas for mounting relays

90Pioneer

NAXJA Forum User
Location
USA
I have several relays I need to mount for some lights I'm installing.

Does anyone have a clean way to install these without just picking a random spot? Maybe some kind of relay bank/holder?
 
Hella makes a nice 4-gang relay block with a splash cover - you can get yours from Susquehanna Motor Sports (www.rallylights.com) Catch - it IS a little pricey, but I like it...

Link: http://www.rallylights.com/hella/Relay_Boxes_and_Fuse_Boxes.asp

Pic:
62943.jpg


5-90
 
I just use a standard relay, tape all of the spade connectors together (for strength), put the whole works into a small pastic bag, seal it with a dab of putty and Zip tie the bag shut, then Zip tie the whole works, up out of the way someplace.
One thing I do, that has saved me a lot of grief, is to salvage a whole box full, off the slotted plastic cable shielding from a junk yard. I don´t mess much with the stock harness, just add my own wires and protect them with plastic sheath, tie them to the stock harness with Zip ties.
I avoid tapping into the existing fuse box, I usually run a seperate (fused) circuit from the battery.
On my last XJ, I installed a small water proof pastic box up near the heater in the engine compartment, with a fuse rack inside. Found the box at a truck stop, parts outlet. Made hooking up the CB ( and linear amp), sterio amp and lights much easier and didn´t load up the marginal stock circuits.
 
I purchased a setup from www.newarkinone.com but it doesn't have a cover. It is individual plastic sockets for standard automotive relays that have a mounting hole on the side. The individual sockets kind of snap together to form a row. They do not come with the metal inserts that crimp to the wire and then snap into the plastic socket. They have to be purchased separately. Anyway, I ordered 4 relays, five sockets, 10 small terminals and 15 large terminals for a total of about $22 back in October. Jeff

Relay:
http://www.newark.com/NewarkWebCommerce/newark/en_US/endecaSearch/partDetail.jsp?SKU=27C6196&N=4

Individual sockets for the relays that snap together and have one mounting hole on the side:
http://www.newark.com/NewarkWebCommerce/newark/en_US/endecaSearch/partDetail.jsp?SKU=90F8247&N=4

Snap in metal terminals for 14-16 AWG wire (crimp on to wire) for the relay sockets:
http://www.newark.com/NewarkWebCommerce/newark/en_US/endecaSearch/partDetail.jsp?SKU=50F999&N=0

Snap in metal terminals for 10-12 AWG wire (crimp on to wire) for the relay sockets:
http://www.newark.com/NewarkWebCommerce/newark/en_US/endecaSearch/partDetail.jsp?SKU=50F1000&N=0

I have also taken advantage of unused relay socket positions in the stock fuse box. This is a bit tedious, but makes for a nice clean install when done. Jeff
 
Good ol' tupperware. :D I bolted it down to the tab that the plastic cover used to be on. cheaperthandirt.com had little metal military firstaid containers (like 9x4x3") for $5. I've got one holding some of the custom wiring underneath my MJ's bed. No pics of it yet, I just did it the other day.
Jeep on!
--Pete

24085119.jpg
 
No pics (I probably should take some) but I mounted 2 light gauge steel shelves, one on each side of the engine bay. One is for all non-lighting supplemental circuits, the driver's side is for all lights (relayed, etc.) I got the components (relays, sockets, ground blocks and fused distribution blocks) from http://www.partsexpress.com. Both shelves have 4 gauge positive and ground leads back to the battery.
 
i Agree with the Hella Idea. The Other neat thing is that have a 16 circuit fuse block that matches the relay box and the boxes snap together.

This is under my hood, I Had to do this when the Stock HO fuseblock caught fire. This runs all the Factory fuses (except the maxi fuses which are in the glovebox) and the factory relay plus the Hi-Lo headlight, Driving lights, and cooling fans.

808664_12_full.jpg


And on the toolbox in the rear This runs the overhead lights, 4 front kc's, each hella side light, and the twin KC backup lights. I have one extra relay circuit that was used for OBA (now i have a york) and will soon be used for Rock lights.

808664_11_full.jpg


Sorry the pic is so blurry i just took it and it was dark so the amera couldn't focus.
Dingo
 
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I just found a doner xj and cut the relay pack off of it leaving as much of the wire on the relay mounts then put a row of them on the firewall, they all slide together so you only need a screw on the first and last one then just spice in what you need. It is also a great place to get extra relays. You can usualy carry this out of picka part for free and to buy at the store is over 20 each...
 
There is a nice relay block in the glove compartment of ZJs too. If you see one at your local pick-n-pull, check it out. It has like 6 or 7 spots for the full size relays and a few for the smaller type too.

Or, you can take apart the stock fuse/relay panel and use any empty spots you may have (things like where the ABS fuse goes on non-ABS jeeps). But you need to take every fuse/relay out... then pull out the plastic liner thing. You can make the pins out of spade connectors by drilling a hole in the right spot. This will hold the spade connector in when the liner-thing is put back into place. It's easier than it sounds...
 
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