After the electrics on the Dakar acting up again, major remediation is called for.
This means: if it carries current, isn’t part of the engine loom, and I didn’t put it there, it’s getting replaced!
Phase I – the stuff that’s broken
- Run new main power feeds from battery II and alternator to …
- Install new fuse box with relays controlled by…
- New Ignition Switch controlling main power via relays on new box.
- Re-wire hazards and indicator lights using existing wiring
- Wire new side/head light switch to existing wiring
In this phase I’ll pick up the existing wiring fore and aft for the lights.
Phase II – the rest of the existing wiring
- Wire Internal Light to Dash switch
- Feed Radio, dash sockets from new fuse board (ACC I)
- Replace wiring to front and rear lights
- Re-wire driving and rear work lights to Battery I.
- New Winch Control to front and repair front winch
- New Winch Control and power to rear and install rear winch
- Investigate and fix wiper stop problem.
- on a related note, install new washer jets and re-wire washer motor to new switch.
- Tear out anything not connected to the Engine ECU that isn’t my wiring and fix what’s broken.
Phase III – new stuff
- Install LED/strobe beacons
- Create new warning light panel to side of existing dash
- Re-wire Ignition, Oil Pressure, and Main beam switches back to new panel.
- Wire in a pair of Anderson Power Poles as ACC II to power amateur radio kit while out in the Dakar
- Install Circuit breaker in parallel with X-charge relay to allow starting from 2nd battery if isolated.
- Install warning light when second battery in circuit, and when second battery isolated when ignition on.
Yeah, lots of work.
So far I’ve got most of the bits, started to assemble the switch panel harness, fuse/relay box, and ignition switch harness. Let’s see how this goes.
To give you an idea of the challenge, this is the space under the steering wheel right now:
And this is the space for the new switch panel: