Electrical System Tech Day - March 5 (1 Viewer)

[emorth]

Automotive Electrical System Tech Days

Game Plan
At the request of several members, the electrical tech day will be split into two parts - classroom and garage. The thinking was; it may be better to have a class first, this way everyone will be familiar with how the electrical system works, how to troubleshoot it and how to fix it, before we get to the garage.

Part 1 will be a classroom & hands-on session to cover the basics of automotive electrical systems, how the various components work and interact, reading a schematic (FJ40), using a volt/ohm/amp meter and troubleshooting techniques. We will also solder, crimp, use shrink tubing and intentionally set some wire on fire to show what happens when things go wrong.

If you have a specific topic you would like to cover during the class, please let me know. Depending upon what it is, I may be able to get (or simulate) the parts, build the circuit, use it as a hands-on example and troubleshoot potential failures during the class. This way we will be sure to cover the specific things you would like to accomplish when we get to the garage in part 2.

If you have a volt meter, please bring it to the class. If you don't have one, don't buy one until you attend the class.

Part 2 will be in a garage so you can work on your vehicle and do the things we prepared for in Part 1.

Details:
Part 1
Classroom and hands-on session
Date: Saturday, March 5
Location: Burke Centre Library, 5935 Freds Oak Road, Burke, VA 22015 (NE corner of Routes 123 & 7100)
Time: 10 - 5

Part 2
Garage session to fix/modify/install/customize electrical "stuff" on your vehicle
Location: Iron Pig Off Road, Toyota Land Cruiser experts

7 Rodney Lane
Fredericksburg, VA 22405
540-361-7400​

Date: 3/19
Time: Starting between 9 & 10 and going until ???


I have received several requests regarding headlight relay installations. During the classroom session we can practice crimping, soldering and heat shrinking and build the cable harness for the headlight relays. After the harness is built, the installation is very simple. I will need to order the relays, connectors and miscellaneous parts. If you are interested in building a headlight relay circuit for your vehicle, please let me know ASAP. Estimated cost for parts (my cost) is about $45. If you have a soldering iron and you plan to make a harness, please bring it to class.


Please let me know if you have any questions, comments, suggestions, criticisms, obscene remarks or rude gestures.

So far, I am ordering parts for:

• StaleAle
• Blue77FJ40
• VonHayek
• SAS
• mcgarrett91
• TRFCSUX

Did I miss anyone?

Directions to Burke Centre Library:

From the west:
I-66 east to Fairfax Co Pkwy (7100) south
Left on Freds Oak Rd ( first left after going under route 123, Ox Rd.)
Library on right

From the south
I-95 north to route 123 north
Right onto Fairfax Co Pkwy (7100) east
Immediate left onto Freds Oak Road
Library on right

From the Beltway 495
Braddock Rd west
Left on Burke Lake Road
Right on Fairfax Co Pkwy (7100)
Right on Freds Oak Rd
Library on right

From Fairfax City
South on Route 123 (Chain Bridge Road which becomes Ox Rd)
Left onto Fairfax Co Pkwy (7100) east
Immediate left onto Freds Oak Road
Library on right

Thanks,
Ed

 

[StaleAle]

Ed -

I will need to do the turn signal/high beam switch trick since I'm upgrading the steering column but sticking with the stock turn signals/taillights. I will bring the turn signal/high beam switch to the meeting on Wed.

 

[Von Hayek]

Looks like an excellent tech day Ed. Looking forward to it.

 

[Blue77FJ40]

Ed -

I will need to do the turn signal/high beam switch trick since I'm upgrading the steering column but sticking with the stock turn signals/taillights. I will bring the turn signal/high beam switch to the meeting on Wed.

?????? which trick is that ??????

 

[Devilmans Hand]

I can bring my cruiser as an example of the super Sweet headlight relay option.
I can also bring a soldering iron and multimeter if people want to play around.

 

[TRFCSUX]

headlights

Ed ,

I would love to do the headlight upgrade but do not know anything about it. New headlights, new bulbs, new harness ?????? Will you be at the meeting ?
Thanks Steve

 

[Blue77FJ40]

Yeah, what he said. For someone with completely stock headlights, what are the components of the upgrade? What type headlight is the upgrade for?

Pics of the components would be sweet.

 

[TRFCSUX]

IPF

Iron Pig has upgrade headlights on sale, sweet.

 

[John Smith]

Ed ,

I would love to do the headlight upgrade but do not know anything about it. New headlights, new bulbs, new harness ?????? Will you be at the meeting ?
Thanks Steve

Yeah, what he said. For someone with completely stock headlights, what are the components of the upgrade? What type headlight is the upgrade for?

Pics of the components would be sweet.

What Ed is talking about is using relays to trigger the low and high beams. You don't run the entire load through the headlight switch like in the stock setup. You gain brightness in your headlights since they are drawing directly from the battery. You also take a huge load off the headlight switch and 20 plus year old wiring. It is a cheap easy upgrade. Two relays, two fuses, two headlight connectors, some wire and connectors.

 

[Devilmans Hand]

Yup. Think before I put the relays in I had nearly a 3volt drop through all the old wiring and switch. It makes a huge difference.

 

[emorth]

Ed -

I will need to do the turn signal/high beam switch trick since I'm upgrading the steering column but sticking with the stock turn signals/taillights. I will bring the turn signal/high beam switch to the meeting on Wed.

Yep, been there, done that. We can do the same thing we did to Tom's truck. Shall I order the parts?

 

[emorth]

?????? which trick is that ??????

Older 40s had combination stop & turn lights. The same bulb did both functions. The turn signal switch interrupts the stop light circuit, otherwise the stop/turn light would stop flashing and stay steady lit when you stepped on the brakes.

Newer 40s have individual stop and turn lamps, this makes the turn signal switch very simple. No need to interrupt the brake light circuit. So if you are going to use a newer turn signal switch, that doesn't have the contacts for the stop light circuit, on an older 40 with combination stop/turn lights, you have to add some additional circuitry to interrupt the stop light circuit to the bulb that is flashing. Does this make sense?

Ed

 

[emorth]

What Ed is talking about is using relays to trigger the low and high beams. You don't run the entire load through the headlight switch like in the stock setup. You gain brightness in your headlights since they are drawing directly from the battery. You also take a huge load off the headlight switch and 20 plus year old wiring. It is a cheap easy upgrade. Two relays, two fuses, two headlight connectors, some wire and connectors.

Yep, what John said. It is pretty much "plug & play" using the existing headlights. The only new connections are to a good power source and a good ground. No other wires to cut or splice. On my 40 with the OEM wires I had 9 volts at the headlights with engine running. After I installed the relays I have 14 volts at the headlights - and I can actually see to drive at night.

 

[emorth]

Ed ,

I would love to do the headlight upgrade but do not know anything about it. New headlights, new bulbs, new harness ?????? Will you be at the meeting ?
Thanks Steve

Same headlights, new harness. Yep, I'll be there.
Ed

 

[StaleAle]

Yep, been there, done that. We can do the same thing we did to Tom's truck. Shall I order the parts?

That's what I had in mind, although I hate to give up the retro floor dimmer switch. Any way to wire it in like a 3-way in a house?...probably just more relays, right!

Please lay in a supply of what you think we might need plus a few extra's...my slobbering skills are rusty. Besides, we might get creative with dome lights or dash lights. Tom is bound and determined to put something chrome on my truck, so maybe an air horn for when he is geezering his way up the trail in front of me.

Also, wouldn't mind a little stealth theft protection wizardry as well....hmmmm

 

[emorth]

That's what I had in mind, although I hate to give up the retro floor dimmer switch. Any way to wire it in like a 3-way in a house?...probably just more relays, right!

Please lay in a supply of what you think we might need plus a few extra's...my slobbering skills are rusty. Besides, we might get creative with dome lights or dash lights. Tom is bound and determined to put something chrome on my truck, so maybe an air horn for when he is geezering his way up the trail in front of me.

Also, wouldn't mind a little stealth theft protection wizardry as well....hmmmm

OK. I like where this is going!!!!

 

[Blue77FJ40]

Thanks for the clarifications John and Ed. Yes, Ed, it makes sense. I wasn't thinking about the different wiring setups for the earlier 40s, but I now see the light (minor pun intended).

Yes, please add me to the supply order, Ed. I'm sure I have all the makings at my shed except the relays and headlight plugs, but please order the works for me just to be sure. I will bring a heat gun and soldering gun.

 

[mcgarrett91]

Ed,

Thanks for lining this up. What do I need to boost the juice to my wipers? Would this be a good opportunity to work on this issue?

Michael

 

[emorth]

Ed,

Thanks for lining this up. What do I need to boost the juice to my wipers? Would this be a good opportunity to work on this issue?

Michael

Hey Michael,
Yes. I have a circuit to boost the juice to the wipers. We can build that circuit during the tech day, as well.

Boost the juice. I like that. Perhaps we should call this the "Boost the Juice" tech day.

Ed

 

[emorth]

Thanks for the clarifications John and Ed. Yes, Ed, it makes sense. I wasn't thinking about the different wiring setups for the earlier 40s, but I now see the light (minor pun intended).

Yes, please add me to the supply order, Ed. I'm sure I have all the makings at my shed except the relays and headlight plugs, but please order the works for me just to be sure. I will bring a heat gun and soldering gun.

Will do & thanks,
Ed