Relays and wiring ect. ?

[the great him]

i posted this up in another area but im gonna post it here too, to try and get as much input as possible, so im redoing so wiring in my truck, mainly all of my off road lights, and setting up some wiring to do a dual electric fan swap. also want to redo my electric fan on my trans cooler as well. but i need some relays. im sick of the cheep relays you get at chain auto parts stores(unless you have a specific brand or part number dont bother, i have run through most of the off the shelf ones and they fall apart) i was wondering if any of you guys have some advice or expertize on this that you could share with me.

-for my fans i think im gonna need a dual 40 amp set up, and a 30 am on my trans cooler, those should be relatively easy to get a hold of. where it gets tricky is with the off road lights. i have 5 accross the top, 3 130w and two 100w lights, i want to put at least two 55w floods on the side, and 2 55w floods on the back -yes i know about LEDs but those cost $$$ and i already have these, they are great quality -PIAAs and i dont want to spend more money to go LED at this time. -the chargins system can handle it so thats not of concern here either. what im looking for is relays and possibly a fuse block unit it one that could be used for this that would look clean but more importantly hold up. i burn through 40a relays(one per light) on my roof rack so i need to come up with a different solution.

thanks

 

[zopperman]

i posted this up in another area but im gonna post it here too, to try and get as much input as possible, so im redoing so wiring in my truck, mainly all of my off road lights, and setting up some wiring to do a dual electric fan swap. also want to redo my electric fan on my trans cooler as well. but i need some relays. im sick of the cheep relays you get at chain auto parts stores(unless you have a specific brand or part number dont bother, i have run through most of the off the shelf ones and they fall apart) i was wondering if any of you guys have some advice or expertize on this that you could share with me.

-for my fans i think im gonna need a dual 40 amp set up, and a 30 am on my trans cooler, those should be relatively easy to get a hold of. where it gets tricky is with the off road lights. i have 5 accross the top, 3 130w and two 100w lights, i want to put at least two 55w floods on the side, and 2 55w floods on the back -yes i know about LEDs but those cost $$$ and i already have these, they are great quality -PIAAs and i dont want to spend more money to go LED at this time. -the chargins system can handle it so thats not of concern here either. what im looking for is relays and possibly a fuse block unit it one that could be used for this that would look clean but more importantly hold up. i burn through 40a relays(one per light) on my roof rack so i need to come up with a different solution.

thanks

Painless Performance Products 30107 Painless Relay Block Kits

Amazon.com: HELLA H84988007 4-Way Mini Relay Box Kit (Bulk Packaged): Automotive

Amazon.com: Blue Sea Systems 5026 ST Blade Fuse Block with Cover: Sports & Outdoors

 

[eddiebx]

i posted this up in another area but im gonna post it here too, to try and get as much input as possible, so im redoing so wiring in my truck, mainly all of my off road lights, and setting up some wiring to do a dual electric fan swap. also want to redo my electric fan on my trans cooler as well. but i need some relays. im sick of the cheep relays you get at chain auto parts stores(unless you have a specific brand or part number dont bother, i have run through most of the off the shelf ones and they fall apart) i was wondering if any of you guys have some advice or expertize on this that you could share with me.

-for my fans i think im gonna need a dual 40 amp set up, and a 30 am on my trans cooler, those should be relatively easy to get a hold of. where it gets tricky is with the off road lights. i have 5 accross the top, 3 130w and two 100w lights, i want to put at least two 55w floods on the side, and 2 55w floods on the back -yes i know about LEDs but those cost $$$ and i already have these, they are great quality -PIAAs and i dont want to spend more money to go LED at this time. -the chargins system can handle it so thats not of concern here either. what im looking for is relays and possibly a fuse block unit it one that could be used for this that would look clean but more importantly hold up. i burn through 40a relays(one per light) on my roof rack so i need to come up with a different solution.

thanks

Are you thinking about trying to put one together yourself, or have one pre-made and just mount it?

I saw this pretty nice looking one someone used on the 5th gen forum, maybe you can try and look into having it made. http://www.toyota-4runner.org/5th-gen-t4rs/106545-new-light-setup-thoughts-please.html#post965116

If you are trying to piece one together yourself, try looking for flux tight relays like this: Flux Tight Relay because they are sealed units and usually survive better in adverse conditions.

If you really want to nerd out, take a look at these relays from Omron and Panasonic, they are OE suppliers and well tested so you know exactly what to expect: Invalid Request (no sure why the link is showing up as invalid request, but it works, lol)

 

[zopperman]

Are you thinking about trying to put one together yourself, or have one pre-made and just mount it?

I saw this pretty nice looking one someone used on the 5th gen forum, maybe you can try and look into having it made. http://www.toyota-4runner.org/5th-gen-t4rs/106545-new-light-setup-thoughts-please.html#post965116

If you are trying to piece one together yourself, try looking for flux tight relays like this: Flux Tight Relay because they are sealed units and usually survive better in adverse conditions.

If you really want to nerd out, take a look at these relays from Omron and Panasonic, they are OE suppliers and well tested so you know exactly what to expect: Invalid Request (no sure why the link is showing up as invalid request, but it works, lol)

that bussman unit is sweet!!

 

[the great him]

i do like that bussmann unit is an awesome unit, i like that. thats what im looking for, i want one "brick" i can mount, something that houses all my relays and fuses together. the only issue with the panisonic relays is the are only 40amp, while that might work for some of my stuff, i would like to run at least a 60 preferably an 80amp relay... my issue has been finding one with that rating.
[MENTION=85512]eddiebx[/MENTION] thanks though for that link to that thread, im gonna have to look into that more tomorrow when i have some spare time.

 

[criera]

You might try potter webster, ive had decent service/luck there. Theyre accross the street from jubitz truck stop in NoPo.

 

[jwyshrek]

How about using one of those old Ford starter solenoids...they were separate from the starter and usually mounted on the inner fender or firewall...

Something like this...

1962-1974 Ford Galaxie 500 Starter Solenoid - Engine Electrical - Standard Motor Products, Fender Mounted 62-74 Galaxie 500 Starter Solenoid - 24247-07042140 - PartsGeek

I think they were made to handle well over 100A.

 

[jwyshrek]

by the way...it is like a large 'capacity' relay...or contactor...

 

[jwyshrek]

ALSO, you might want to try some professional grade relays instead of that cheap junk you get at the local auto store...I've had bad luck with those as well.

They are not cheap but...

Your Search Results | Newark | Results

 

[eddiebx]

i do like that bussmann unit is an awesome unit, i like that. thats what im looking for, i want one "brick" i can mount, something that houses all my relays and fuses together. the only issue with the panisonic relays is the are only 40amp, while that might work for some of my stuff, i would like to run at least a 60 preferably an 80amp relay... my issue has been finding one with that rating.
[MENTION=85512]eddiebx[/MENTION] thanks though for that link to that thread, im gonna have to look into that more tomorrow when i have some spare time.

This might be overkill but if you're trying to push such high current reliably, maybe you can just step up to one of these guys?

IBS 12V / 200A Relay

Just of out curiosity, what are you running that needs such a high switching current? And could you possibly split them up on to separate relays to lighten the load?

 

[mace.]

I saw this pretty nice looking one someone used on the 5th gen forum, maybe you can try and look into having it made. http://www.toyota-4runner.org/5th-gen-t4rs/106545-new-light-setup-thoughts-please.html#post965116

I have been extremely pleased with the wired wagon setup, but word was that they stopped building It. I know there was talk about someone on the forum trying to build a few. Don't think it ever happened. I would be willing to purchase the crimpers and supplies if someone wanted to help with the electrical diagrams. I definitely want another and would be willing to build for others on the forum.

 

[eddiebx]

I have been extremely pleased with the wired wagon setup, but word was that they stopped building It. I know there was talk about someone on the forum trying to build a few. Don't think it ever happened. I would be willing to purchase the crimpers and supplies if someone wanted to help with the electrical diagrams. I definitely want another and would be willing to build for others on the forum.

Oh that sucks! If you ever need help with the wiring I'd be glad to take a look and/or help you figure out the circuit layout.

 

[the great him]

[MENTION=85512]eddiebx[/MENTION] im trying to redo all of my aux wiring ect, for my lights, i have 7 on the rack currently, 5 upfront -3 130w PIAAs, and 2 100w PIAAs, then on the back i have 2 55w PIAA floods, im also wanting to add two more of those on the side for camp lights ect. then i have 2 big IPFs on the bumper as well as 2 more PIAAs that are 120w... yes i know about LEDs but my money is already invested into my current setup, and so im going to stick with them, i like them as well. -nothing against LEDs but i dont have $2k to shell out for all new lighting for the same quality LEDs as PIAA has in halogen... i dont use them all the time, and honestly i havent had my rack on my truck in almost a year, but still i want to put it on there before winter and the long nights settle back in. its nice to have all that light when im out deep in the woods or out in the middle of no where in easter wa/or with nothing for miles, not to mention it helps with SAR and setting up LZ or even clearing areas visually at night -you can never have too much lighting, never

i want everything to look nice and tidy, not like a hack job or after thought. i already have an external fuse block(6 station) that is full so im gonna need to either add onto that or get a bigger one.

 

[mace.]

Oh that sucks! If you ever need help with the wiring I'd be glad to take a look and/or help you figure out the circuit layout.

Awesome, I'll definitely take you up on that. I'm heading out to Park City middle of next month for my wedding. Once back the future wifey knows that the big mods will begin. I'll have the time then to give aux relay boxes a go.

 

[eddiebx]

[MENTION=85512]eddiebx[/MENTION] im trying to redo all of my aux wiring ect, for my lights, i have 7 on the rack currently, 5 upfront -3 130w PIAAs, and 2 100w PIAAs, then on the back i have 2 55w PIAA floods, im also wanting to add two more of those on the side for camp lights ect. then i have 2 big IPFs on the bumper as well as 2 more PIAAs that are 120w...

Ain't nothing wrong with good ol' fashion high wattage halogens to light up your path

I am not sure how you have all the aux lights wired up currently, but since you are thinking about redoing the existing wiring...have you considered just splitting them up onto separate relays and circuits?

For example, your three highest power 130w PIAAs on one circuit is only ~30 amperes and change, so a higher quality 40A relay should be able to handle that all day long no problem. The benefit of sticking with smaller load circuits is that you can stick to thinner gauge wires which would be easier to route all over the place, not to mention cheaper.

Once you get into 60-80A stuff you need to step up to maybe 8 ga. wiring or thicker depending on how long your run is to compensate for voltage drop. Could end up to be a pain in the rear to fish that around IMO.

 

[zopperman]

Ain't nothing wrong with good ol' fashion high wattage halogens to light up your path

I am not sure how you have all the aux lights wired up currently, but since you are thinking about redoing the existing wiring...have you considered just splitting them up onto separate relays and circuits?

For example, your three highest power 130w PIAAs on one circuit is only ~30 amperes and change, so a higher quality 40A relay should be able to handle that all day long no problem. The benefit of sticking with smaller load circuits is that you can stick to thinner gauge wires which would be easier to route all over the place, not to mention cheaper.

Once you get into 60-80A stuff you need to step up to maybe 8 ga. wiring or thicker depending on how long your run is to compensate for voltage drop. Could end up to be a pain in the rear to fish that around IMO.

This is exactly what I would do.
I converted a KC light to 55w HID with a DDM ballast and it's F'ing sweet. Just saying :wink2:

 

[the great him]

Ain't nothing wrong with good ol' fashion high wattage halogens to light up your path

I am not sure how you have all the aux lights wired up currently, but since you are thinking about redoing the existing wiring...have you considered just splitting them up onto separate relays and circuits?

For example, your three highest power 130w PIAAs on one circuit is only ~30 amperes and change, so a higher quality 40A relay should be able to handle that all day long no problem. The benefit of sticking with smaller load circuits is that you can stick to thinner gauge wires which would be easier to route all over the place, not to mention cheaper.

Once you get into 60-80A stuff you need to step up to maybe 8 ga. wiring or thicker depending on how long your run is to compensate for voltage drop. Could end up to be a pain in the rear to fish that around IMO.

i already had that basic set up, i had two 40a relays, one ran the 3 big lights, and the other ran the two smaller lights, they both burned up and melted the housings and while they didnt short out they got so hot they started to "drip"... so if two 100w lights ate up a 40a relay im gonna want at least a 50 -preferably a 60w for them, i was thinking about going with an individual relay for each of the130w lights at like a 40a relay. i am running 10awg wire to the 130w lights from the relay and 12awg to the 100w ones. the run is from the firewall next to the wiper motor, over to the drivers side in through a gromit in the firewall down behind the kick panel and under the door sill then up the B pillar and up to the roof and to the rack then to the lights, in all i might have 10' of wire, i know its kinda long but im not getting any voltage drop to speak of.

i basically am just wanting to clean up things and centrally locate all my aux stuff into something that look factory and not have something that looks aftermarket... idealy id like to put this all in the fuse pox under the hood i just wish i knew someone who knew this kinda stuff better than me lol