So I start fabricating the bracket today to hold the circuit breaker and auxiliary fuse panel for the upcoming electrical accessories. I fabricated it from a piece of 1/8" x 12" x 12" 3003-H14 aluminum I ordered off of Amazon. I made the last bracket out of the same material and it proved to be easy to bend and plenty sturdy for my purposes.
As always, the first step was to make a cardboard template for the space in question. I chose to leave as much material as possible for reconfiguring in the future as I intend to add a dual battery controller, some relays, and perhaps relocate the winch solenoid under the hood. That's all in the future though, for now I just need the base piece.
20141213-P1010239 by
Tim Souza, on Flickr
A few minutes with a guide and jig saw and I had myself a 2D version.
20141214-P1010241 by
Tim Souza, on Flickr
Being a bit of a stickler for the details I spent a good 20 minutes or so with an angle grinder and flap disk grinding the corners into nice radii, breaking edges, and removing any burrs left behind.
The next step was to start drilling holes. 10 holes total need to go in though I only did 9 today. The missing hole is for an additional support on the inboard side of the bracket. I haven't made up my mind as to whether or not I'd like to run the support down to the bolt holding the breathers or have the support with two 90 degree bends and fasten it at the fuse box. I'm leaning towards the former but need to pop under the hood and take a look again before I drill the final hole.
Anyway, I got the all the mounting holes drilled and demurred. The bracket will eventually get paint + primer but being that my garage is not heated, it may have to wait til warmer weather rolls around. I still need to throw the 80 degree bend in it, a bit tough given that I don't have anything good to clamp it with. Perhaps the fellas in the shop at work won't mind me hopping in there for a second...
The final (2D) product! I can't wait to start wiring, it's a skill I've always wanted to learn.
20141214-P1010242 by
Tim Souza, on Flickr