Switch Box gen II
February 17 2010 | Posted in: ElectricalAfter almost melting down my XJ with my old gen I switch box, I decided to build a new one from scratch.
I started out with the basic measurements from the switch box that I had purchased, and made a few modifications that I wanted in a switch box. So with a pair of scissors and some poster board, I made a few mockups:
After I found the design that gave me the best fit while still giving me the extra space for wiring, I drew up the plans so I could bend it out of a single piece of sheet metal:
Because, at the time of making this version, I lived in an apartment, I decided to rivet the box together over welding it closed.
Picked up a sheet of sheet metal from the local hardware store:
Forgive the next few pictures, but I had my camera on the wrong settings and I didn’t notice this until afterwards.
Trace out the pattern on the sheet:
Drill out the corners of the bends. I found that this keeps the sheet from cracking/tearing and it allows for tighter bends in the corners:
Next I used a pair of metal sheers to cut out the shape then used a rotary tool to cut out the slots in the wings:
Drilled out the 7 holes for the switches:
Then drilled out the holes for the LED indicator lights:
Next I drilled out the holes for the rivits:
I then proceeded to bend up the box. You can see in some of the pictures that I used heat to help the bending along. I was MacGyvering the bends using any hard object that I could clamp to the metal to give me a surface to bend against.
Just like a cooking show.. **POOF** Here was the first test fitting. If you look at the next 2 pictures, you can see why I decided to use slots in the wings. It allows for a little bit of adjustment.
I then did all of the wiring and stuffed it all inside of the box. This setup doesn’t need the cutting of the headliner like my old one did:
And here’s the fully wired, painted, and installed box:
The switches were wired as following:
- Master power – this needs to be on before any of the other switches will function
- ARB air pump
- ARB rear locker
- ARB front locker
- Roof rack mounted lights (outside 2)
- Roof rack mounted lights (inside 2)
- Bumper mounted fog lights
Here’s a simple wiring diagram of how it was wired
You will notice that I also wired mine up so the lockers couldn’t be engaged unless the pump was engaged. I figured this might help me from accidentally locking the lockers. The writeup for the Relay Box can be found here.
2 Responses to “Switch Box gen II”
May 12th, 2010 at 9:11 am
I trust you would not mind if I placed a part of this site on my univeristy blog?
May 17th, 2010 at 7:09 pm
I wouldn’t mind at all. Go for it.