Replacement Relay Socket Panel, Updated: Version 3 - Solid State Relays and Fuse Panel Replacement |
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Replacement Relay Socket Panel, Updated: Version 3 - Solid State Relays and Fuse Panel Replacement |
Evan0 |
Apr 30 2017, 10:12 AM
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#1
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Newbie Group: Members Posts: 44 Joined: 13-February 17 From: Southern California Member No.: 20,837 Region Association: Southern California |
Update 3 Post
I've been rewiring my car for the last few weeks and part of that was replacing the factory fuse panel with one that uses modern fuse from JWest Engineering. I was unhappy with the existing relay sockets that I found. As a result of that, I designed and printed a monolithic fuse socket for all the relays, buzzer, and flasher unit. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1493568735.1.jpg) After mounting it to the fuse panel. The buzzer is a Hella H35394001. The horn, blower, and fog relays are Hella 933332051. The flasher unit is a Hella 009492101. The head light relay is a modern reproduction of the VW one. Still waiting on the flasher unit to ship. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1493568735.2.jpg) I'll be posting the STL files, Bill of Materials, and instructions after I've worked out a few kinks. I would love any feedback or suggestions on improvements. |
Evan0 |
Aug 14 2017, 10:17 PM
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#2
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Newbie Group: Members Posts: 44 Joined: 13-February 17 From: Southern California Member No.: 20,837 Region Association: Southern California |
It's been a few weeks and the first prototype for version 3 are complete. First some background on why version 3 is so drastically different. Between the combination headlight relay, buzzer and other relays, the cost for just the relays was easily over $100. The LED flasher unit from Hella took over 3 months from when I first ordered it to when it arrived. Also the sheer size of the relays and its mount weren't great for placement or installation.
Version 3 consists of a completely custom solution for all the components needed to run a 914. The combination relay, flasher and buzzer are all replicated using discrete logic and solid state relays. The relays are rated for 60 volts and up to 40A peak and 32A continuous. Best part of the this design is that even at a single unit it only costs about $70. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770640.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.2.jpg) The relay board assembly is designed fit with its heatsink to the JWest fuse panel. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.4.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.5.jpg) Since I heard a lot of complaints about the JWest panel, I thought I would take a stab at the problem. The terminals emulate the factory panel, with the correct terminals bused together, and it includes the tilt toward the front of the car. It uses standard ATO fuses. This piece would replace the factory fuse block and integrates my new solid state relay solution. A 1.5mm laser etched plate would sit on the front of the fuse block and provide markings and indication. I didn't get that done in time, but it's not critical. (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.6.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.7.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.8.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-20837-1502770641.9.jpg) I hope this version will be the one to makes it to production. Feedback, improvements, and comments are appreciated. The first couple units are going to be stress tested over the next couple of weeks to validate the design. |
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