Installing extra stuff in fuse box?

MattW

MattW

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I want to fit an extra ignition switched relay and inline fuse to my 1100.

As there's a nice space in the fuse box in front of the fuse carrier, it seems a good idea to try and put it in there:

<a href="https://picasaweb.google.com/lh/photo/-lv3p1YFi3u8qHIqd0NJ8kOOAeJkWHiivqDz0FeWdvU?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-tCk1Zn0utSQ/TmdrjEQP-gI/AAAAAAAAFMc/tLM0btTV3og/s800/IMG_5998.JPG" height="800" width="600" /></a>

It also looks a good place to pick up an 'ignition on' feed to trigger the relay.

I don't really want to have to remove the fuse box but I know others have done this sort of thing so before I start hacking things apart can anyone tell me:

  1. The best way / position to get cables into and out of the fuse box?
  2. If it's possible to pick up an ignition switched feed from inside the box (or would it be best to tap a suitable live outside the box and run a cable into the box to trigger the relay)?
  3. Anything else I've not thought of? :D

Any pointers gratefully received.

ta
Matt
 
Hi,

There's where I put my ABS relay after making the mod. I had to drill the fusebox to get the cables in though... Not actually drill but enlarge the hole in the bottom, where water should come out if accumulated :D

Dan.
 
Thats where my Relay went.

Live feed taken straight from battery. Control wire taken from headlight (Aux lamps)

Wires were fed up through the bottom of the box paralelling the wires that feed up that way.

Try to hide your coloured wires if used as they are pretty obvious amongst all the black stuff in that area.
 
The fuse holder section in the box comes out separately. Plenty of live/switched cables in there and enough room to play around.

I've got my "secret" fuel pump security key operated cut off mounted in the side of the box. :D
 
Thanks for the replies everyone.

Steptoe said:
The fuse holder section in the box comes out separately. Plenty of live/switched cables in there and enough room to play around.

I've got my "secret" fuel pump security key operated cut off mounted in the side of the box. :D
Click to expand...

Thanks Steptoe - I did wonder if the fuse holder comes out on its own but I couldn't work out how :rolleyes:

I ended up taking a switched live off the brake light switch feed (which is in a handy position next to the fuse box). I routed it into the box with my other new cables through a hole drilled in the back (into the empty space next to the fuse holder). I'll seal the hole up with a blob of mastic when I'm done.

Nearly finished now - just got to lift the tank and hook up the new fused live and earth to the battery :thumb2
 
And done :thumb2

I've now got an ignition switched power feed into my Vern topbox and a flying lead I can poke up in front of the seat and into my tankbag. All with quick release waterproof 1/4 turn bayonet connectors.

Thanks for the advice :thumb2
 
Sure.
These are the ones I used (didn't have the straight socket handy to take a pic of) :

<a href="https://picasaweb.google.com/lh/photo/ucT8zpofHPbdoqudsK5g70OOAeJkWHiivqDz0FeWdvU?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-aSpAc2jVxrc/TmfYf9ekZyI/AAAAAAAAFMk/Sq_IlnoL_O4/s800/IMG_6001.JPG" height="600" width="800" /></a>

I used the panel fitting plug in the base of my topbox and the right angled socket to connect to it. I've used a straight plug / socket pair for the tankbag lead. They come with moulded on 1m long flying leads. There are lots of possible pin 'ways' - I used three way 10 Amp fittings (one way unused but there for possible future use).

<a href="https://picasaweb.google.com/lh/photo/fRiygL8pN6WO0q5-CZEVj0OOAeJkWHiivqDz0FeWdvU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-OT9LsSdynZc/TmfYiFz-d4I/AAAAAAAAFMs/Z9okYLIU7GQ/s800/IMG_6003.JPG" height="600" width="800" /></a>

The panel plug is a solder fitting:

<a href="https://picasaweb.google.com/lh/photo/LU6J8kbfQzYcc4IXHRgDYkOOAeJkWHiivqDz0FeWdvU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-O53F8azt5vM/TmfYhFI64vI/AAAAAAAAFMo/ueYdnboOj88/s800/IMG_6002.JPG" height="600" width="800" /></a>

All bought from Farnell:

Panel fitting plug:
http://uk.farnell.com/jsp/search/productdetail.jsp?SKU=1860686

Right angled socket:
http://uk.farnell.com/jsp/search/productdetail.jsp?SKU=1860711

Straight plug:
http://uk.farnell.com/jsp/search/productdetail.jsp?SKU=1860723

Straight socket:
http://uk.farnell.com/jsp/search/productdetail.jsp?SKU=1860700

I also bought a couple of caps to seal unused plugs / sockets.

cheers

Matt
 
Thanks.

I have been looking so long for stuff like that. Christmas has come early.:beerjug:
 
I first came across these plugs on a USA purchased set of extra lights for some Givi Box Panniers on my Bandit. (Which were very expensive, but look cool) I looked through all the web sites for car electronics and drew a blank and also E Bay in my bid to get some decent priced ones.

I can see some future projects on my ally boxes when I get them. And the ability to have a good comms setup.

Once again cheers mate.
 
B4ndit said:
I first came across these plugs on a USA purchased set of extra lights for some Givi Box Panniers on my Bandit. (Which were very expensive, but look cool) I looked through all the web sites for car electronics and drew a blank and also E Bay in my bid to get some decent priced ones.

I can see some future projects on my ally boxes when I get them. And the ability to have a good comms setup.

Once again cheers mate.
Click to expand...

No worries - glad to help :thumb
 
You can also buy piggy back fuse holders, you remove the fuse and put them in, replace the original fuse in it and add another, there is a flying lead off that powers your new item.

$(KGrHqIOKigE3y6TSVRwBO!lLHeb8g~~_35.JPG
 
AndrewD said:
You can also buy piggy back fuse holders, you remove the fuse and put them in, replace the original fuse in it and add another, there is a flying lead off that powers your new item.

$(KGrHqIOKigE3y6TSVRwBO!lLHeb8g~~_35.JPG
Click to expand...

I'm not sure that these would fit in the standard fuse box and allow you to refit the lid?
 
MattW said:
I'm not sure that these would fit in the standard fuse box and allow you to refit the lid?
Click to expand...

Just fits, but a similar thing can be made with a couple of spade crimps that is flexible or just to extend piggy back.
 
AndrewD said:
Just fits, but a similar thing can be made with a couple of spade crimps that is flexible or just to extend piggy back.
Click to expand...

Good to know :thumb2

However, now I've done the job, I'm pretty pleased how it turned out.
 
Is it possible to remove the fuse box without first having to dismantle the rear half of the bike ie. remove hugger and go in from unneath?

Admiittedly I did try to find out in a poorly lit garage one evening recently but couldn't see how to do it.

Any top tips on this one, much appreciated.
 
Green Boy said:
Is it possible to remove the fuse box without first having to dismantle the rear half of the bike ie. remove hugger and go in from unneath?

Admiittedly I did try to find out in a poorly lit garage one evening recently but couldn't see how to do it.

Any top tips on this one, much appreciated.
Click to expand...


Yes.

Believe it or not, it will come up out between the frame rails, although it is either a piss easy job, or a nightmare that will have you swearing at it for an hour.

Sometimes it comes out like a wet pingpongball in a berlin nightclub, but wont go back in, sometimes it feels like it'll never come out but drops back in at first go....

There are two (maybe 4, I cant remember ) phirrips screws on the outer sides...one (on mine anyway) is a bugger to get to, hidden under the frame.

Then pull it out, using all the space you can make by going diagonally if you see what I mean.

The box itself is made of fairly resilient plastic, and has yet to suffer damage even though once or twice I got a bit medieval on it with a pair of screwdrivers :D

Before you replace it, make damn sure everything is done, taped, cable tied and sorted out......if you spend half an hour with it being awkward going back in, you won't want to be getting it back out again to retrieve the roll of insulting tape that you left in there.

DAMHIK :blast

By the way...before you go work on it, print this off and you can stick it on the underside of the lid while you're at it ...courtesy of that nice Mr Whatton :thumb


attachment.php


CLICK HERE FOR KEV'S WORD DOC TO PRINT
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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