My relay box construction, use as a guide if you wish ($26 project)
Not very involved project, but I'm happy with the product, thought I'd share
Accompanied by the relay box pics at http://photos.yahoo.com/jwfowble
Not having any new parts for my stereo left me bored. I decided to make a unit which would enclose the relay I'd purchased and provide terminals for the relay connections. While I was at it, I figured that I could use this to provide remote wire switched power for any neons I might decide to put in (voyeurmods.com had some 4" dual blub cold cathodes on sale).
274-623 - 8 position speaker terminal $5.99
275-690 - spst toggle $2.59
270-1237 - mini-blade fuse holder $2.49
270-1803 - 5"x2.5"x2" project box $3.69
270-1089 - 3 amp mini-fuses (3 pcs) $1.59
E5000 - Bosch SPDT relay with socket - $9
Things you need to have -
soldering iron / solder
misc screws, bolts
cutting devices (dremel and drill)
I had purchased a relay from crutchfield when I bought a wiring harness and din
tools. I set out for radioshack for the other parts I would need.
Radioshack isn't the cheapest place, but they do allow purchases in small
quantities so I settled for them. If you search around, you can probably
substitute cheaper items.
So, after purchasing all the items (pic: the parts), i made a wiring diagram of
how the connections should go (pic: wiring diagram). Use a pencil and
straightedge (perhaps a ruler with mm markingS) to mark the cut for the speaker
terminals, the nut for the switch to mark the cut for the rocker switch, and a
spot for mounting the relay to the wall of the project box. A few cuts (watch for
melting plastic), drilling out the screw holes of the speaker termanals, some
grinding of the inner ridge at the mount point for the relay, and one little
locking "notch" that keeps the switch from rotating and you end up with a place to
work. With the relay mounted (pic: the box).
I then set out to do the "easy" part of wiring the speaker terminals. I connected
all the ground points with short pieces of excess remote wire that came with my
kit and slipped heatshrink around my connection (it doesn't cover all the way to
the terminal, but it does provide a little support and some shielding, didn't
finalize the heatshrink on one terminal so relay can be connected later). I then
wired all the switched remote terminals I wanted together (similar method). I
attached a few short leads of tinned wire (pic: always tin the wire, makes
soldering that much faster) so that I could more easily make my connections with
the larger wires (pic: wiring). At this time, I also used a piece of dual
conductor speaker wire to make the connection to my switch. Once my switch had
wires attached, it was time to start putting pieces in the box and then conencting
the wires (they have to be soldered with wiring inside the box).
A list of the connections that still need to be made:
inline fuse end to +12v terminal
other inline fuse end to the +12v (red wire, pole 30) of relay
switched 12v (white wire, pole 87) to the switched connectors (the one you left unheatshrinked)
ground connector (black wire, pole 85) to one of the ground connectors (the one you left unheatshrinked)
one end of switch wire to the remote lead (note: be sure you have the switch's retaining nut threaded over the dual conductor wire so that you can use it)
other end of switch wire to the switch source of the relay (green wire, pole 86)
After all those connections are made (this is where the harness of the relay is a
great thing, it allows you to make a lot of these connections while leaving the
wires going through the speaker terminal hole) (pic: box all together) you can
screw things down (pic, pretty box).
A few short wires with spades on one end, tinned on the other, you can then
connect your remote wire directly into the remote input speaker terminal, the
ground and 12v input (I used an amp's terminals to attach the spades) into the
appropriate input terminals on the box, and then I ran a wire from the "extra" 12v
switched that I'd made to be the remote signal for my amp.
After this, I've gained the safety of a fused relay, the easy speaker terminal
type connection, and two outlets that I can hook neons up to very easily.
So, if anyone feels like a project, here's a simple one that will be a long
lasting piece of equipment).
97 VW Jetta - building a system from parts in my old 85 Jetta
HU: Pioneer P740MP with 12 disc changer
Front: 3.5" JBL GTO302s in dash
5.25" Cerwin Vega Vega Series 502s in door
Amped: US Acoustics USX-2050 @ 2 ohm
Rear: Stock components
Sub: Single 12" Vega 124 in a cheap bandpass box
Sub Amp:US Acoustics USX-2150 bridged