Triple-purpose JK Build

[jsmoriss]

In-cab Winch Controller for 9.5si -- Done!

Yesterday my father-in-law came over, and while he was working on the switch wiring, I ran some wires and carved-up the plastic behind the console some more. I tried to run all the wiring I'd need, 'cause some grommets are maxed out. So I ran the winch cable into the cab, including a small pressure hose for an up-coming gauge, and some wires from the eventual winch on/off relay to ground a BIC going to the trailer (so I don't suck the trailer's batteries when I winch). I also ran the illumination circuit for the gauges, some wires for the voltage gauge (backup battery), an ignition wire to trigger a second fuse block, a harness for the BIC controller (and associated LEDs).

I also installed the electronic throttle controller. What a PITA -- I had to remove the amplifier to mount it properly.

My father-in-law working on the winch and BIC switches:

Ready to install after tie-wrapping all the wire harnesses in place:

And finally installed:

I'm also working on some new gauges, which I hope will be finished this afternoon. They show voltage on the backup battery, and air pressure in the air tanks:

The air tanks -- approx. 2 x 6 gallons -- should be installed later this week. They'll be going on the roof rack, right behind the Hannibal awning.

js.

 

[jsmoriss]

FYI - For future readers that might want to do this with their Warn 9.5 winch (the 9.5si and 9.5ti seem to use the same remote wiring), here's the remote layout:

And the PDF for a larger view:

http://public.mvlan.net/content/Jeep/Projects/In-cab 9.5si Winch Remote/Warn 9.5si 6 Wire Remote.pdf

The LED is connected across a 1N4007 diode, and the 1000 ohms resistance is simply there to drop the voltage for the LED.

Here's another wiring diagram "cruiseroutfit" posted in another thread:

For my in-cab remote, the two left-side LEDs are for the winch. The green LED says there's power to the winch (and the in-cab remote cable is plugged into the winch), and the red LED behaves the same as on the Warn remote (flashes for error conditions).

js.

 

[jsmoriss]

Finished wiring the gauges and installed the air tanks (right behind the awning)...

I still have to cleanup the wiring for the backup lights -- I'll probably get rid of that connector and solder the wires instead -- and run the air hose under body to the tanks. On Thursday my father-in-law and I should start mounting the control panel for the backup battery. There are two BICs (one for the backup battery, and one for the trailer), a fuse block, two relays, and a 150A fuse for the main battery cable. Once that panel is in place, we'll drill a hole in the firewall for the bulkhead, and then run the main cables. There's a new rear bumper on the way too, so that should be fun!

js.

 

[jsmoriss]

Added a new rear bumper on Saturday...

I've spent the last 2 days wrestling with SWR issues, and it's driving me up the wall. My first CB install was really easy, but then rust got into some ground connections, and the coax broke from bending with the tailgate. I re-did everything -- new antenna, mount, and coax -- but can't get the great SWR I used to have. I really hope I can find the problem before Thursday (leaving for Maine Jeep Jamboree)...

js.

 

[p1michaud]

I like that bumper!

Added a new rear bumper on Saturday...

Very cool bumper. Who makes it?

By the way, I met a guy at our local Jeep trail run (Saint John, NB) this past August and he told me a story about this guy from Quebec who had a very cool green JK but had some tree troubles at a Jeep jamboree. I said, really that's funny he's on Expediton Portal. Small world.

Cheers,
P

 

[jsmoriss]

Very cool bumper. Who makes it?

Expedition One. Nice bumper, but no provisions for jerry cans, so will have to fab my own solution...

By the way, I met a guy at our local Jeep trail run (Saint John, NB) this past August and he told me a story about this guy from Quebec who had a very cool green JK but had some tree troubles at a Jeep jamboree. I said, really that's funny he's on Expediton Portal. Small world.

Yeah, that's pretty funny. I'm on JK-Forum and Expo -- there are only a few of us that are on both sites.

js.

 

[jsmoriss]

The control panel for the backup & trailer battery is coming along...

I forgot to mention that I added a sector shaft brace a little while ago. Here's the connection at the sector shaft:

And the other side mounted to the frame:

I also replaced the front axle shafts and u-joints for Surperior shafts and CTM u-joints. The CTMs are way overkill, but what the heck.

Having to replace the seals was a bit of a surprise.

We were supposed to change out the rear shafts as well, but ran out of time...

js.

 

[Momrocks]

Wow

All your work has resulted in a top shelf rig. Very inspirational. If I wasn't so cheap, unskilled, but most importantly, lazy...I could build a world class rig like yours too. You are really doing things up right.

 

[elias]

Yeah, that's pretty funny. I'm on JK-Forum and Expo -- there are only a few of us that are on both sites.

js.

Actually, more of us than you think. eepwall:

 

[Gear]

elias
Quote:
Originally Posted by jsmoriss
Yeah, that's pretty funny. I'm on JK-Forum and Expo -- there are only a few of us that are on both sites.

js.


Actually, more of us than you think.

It is too bad that JK-Forum sensors everyones posts. If it is not on the list of paying vendors you don't get a say. That is why more people are jumping ship. This was an interesting read over on JK Owners.

http://www.jkowners.com/forum/showthread.php?t=3441

 

[absolute]

That bumper looks great!

I enjoy seeing new posts on your JK! Your details are excellent!



*Gear - Thanks for the Read! *

 

[Dave Bennett]

Amazing build, and great thread! :bowdown:

 

[jsmoriss]

I've spent the last 2 days wrestling with SWR issues, and it's driving me up the wall. My first CB install was really easy, but then rust got into some ground connections, and the coax broke from bending with the tailgate. I re-did everything -- new antenna, mount, and coax -- but can't get the great SWR I used to have. I really hope I can find the problem before Thursday (leaving for Maine Jeep Jamboree)...

FYI - I started another thread about this around the same time, and the day before leaving, found the problem.

http://expeditionportal.com/forum/showthread.php?t=19220

I'd tried various lengths of coax (9, 18, 18+9, and 30), but none of them worked until I tried 18+18. My SWR dropped from 3-4 to 1.1-1.2. Go figure.

js.

 

[jsmoriss]

Looking for a CB name for my rig...

If anyone has any suggestions, please chime in. Off the top of my head, I have:

- Expo4
- Overland4
- Triple4
- Jk42

The 4 being for the 4 doors, and the 2 being for 2 people. And anyway, isn't 42 the answer to everything? If only I knew the question. :-D

js.

 

[Gear]

I like - js. You have enough information out there that most would know who it is.