BleepinJeep's DIY: Relay and Fuse Box
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- Опубликовано: 23 фев 2014
- In this video I'll show you how to make your own custom diy relay and fuse box. Similar boxes like the sPod and Blue Sea Systems fuse and relay panels with less fuses and less relays can go for $450 or more online... But after watching this how to you can make your own for about $35. Follow along and I'll show you step by step how to wire the fuses, relays, and even switches to power your accessories, lights, and more.
Watch the Entire Zombie Jeep Build Playlist from Start to Finish: bit.ly/1QnBiVu
The Wiring Diagram I used from SirGCal and found on the JeepForum Website (third image down): www.jeepforum.com/forum/f20/wi...
And a Handy Wire Gauge Chart: www.offroaders.com/tech/12-vol...
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Disclaimer - This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee, wrangler, or any jeep vehicle. May be too intense for some viewers and children under 30 years of age. Please remain seated until the ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in jeep mirrors may be farther than they appear. 
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That's one of the best tutorials on wiring a simple offroad rig. You show the fundamentals, you show how to use it in practice and on top of that you add your own tips & tricks based on experience. Now that's a great mix of knowledge. So many tutorial on YT only cover the basics. This is a complete package.
This is the best edited and thought out "how to" video I've seen on RUclips. Thanks for putting this together and posting it.
This guy is just like me, HE TOOK APART CRIMPS TO RE USE THEM! 2 days ago I pulled apart the micro switch on my cars RKE remote. Pulled the thin metal cap off to discover no convex conductive button to short the 3 traces. Being as my PANIC button only has the range to be annoying, I took the convex flex button out of that and replaced it in my unlock button. Jeepin Brother From Another Bleepin Mother :)
This dude is the best I swear. And to the one person who disliked this video, there is always a hater, isn't there. Thanks for all the help Jeeper!!!
Always .... and they suck. I'm back to watch it again so that I can do it as well.
Thanks you are the first person to explain your way, the way i was thinking and gave me peace of mind that i was on the right track. I am busy with an Ford Fairlain 500 wiring that was an disaster for a friend that was ripped off. I would like to share my input photos with you A great thanks to you well done, Jakes from SA
I love the idea of using CAT 5 for your switch-relay signaling cable! It's so obvious and convienient to get 4 switched circuits in a compact routing Great idea & so better than running 8 (16guage) wires!
I figured out how to remove the maxi-fuse portion so now have the ability to add higher amp accessories. Couldn’t have done it without this video guiding the initial disassembly. Thanks Matt
Maan that is great, I went to crazy rays this weekend and got two fuse boxes and will be doing this same set up this weekend coming , It cuts down so much wiring through the dash board for all of my auxiliary switches and appliances. Great video thanks again Bleepinjeep.
Reminds me of when my buddys fuse box melted on his 94 yj and I had to get a new box and transfer every one of those connections from the burnt one to the new one this was like 15 years ago and he is still daily driving it....it was like my first major electrical repair and shops where asking 1000s to do it and it was not sooooo hard ....but watching this would have helped sooo much....great work mat thanks for sharing
made this bad boy a few months back and just got to actually install it in my jeep. it works like a charm! deciding where to mount was the hardest part but that was in my tj.
You just saved me 300 that I was going to spend with Summit ! Soooo simple the way you lay it out! Many thanks bro!
Thank you! Always well prepared videos. As you said, way better than wires, fuses, relays and such everywhere in the vehicle.
Your Disclaimer is absolute gold!
nobody reads anymore😔
Thanks for this video, I really feel like I learned something very useful. I have electrical problems in one of my older cars and have been ignorant on the whole subject of electric in cars. Whilst this is not exactly a diagnosis video, it gives insight as to how things work and I for one find it helpful.. Hello from TX
Andrew Davis ⛔🈚🗻🎡
Man, this is 100% everything I've needed for my 4runner. Props on designing it! Thank you so much!
+Zach Goode thanks for watching!
Thx a lot matt for the extreamly easy DIY relay box. Finished my box last night, tested, and ready to install!!! Now to start on TMR Customs relay box.
Matthew Wagner awesome, glad I could help. post a pic on the FB page so we can see it!
Great tutorial Matt! Thanks for putting it together! Oh, and great idea with the dielectric grease!
Thanks for linking me to this video. Exactly what I was looking for! Thinking this would be perfect with a dual battery setup.
just picked one up today to work on this week sometime, thanks for the great how to Matt!
You are a life saver. Almost spent money on a painless kit.
Yuuuuuup i saved this for future use!!! Very detailed and easy to follow. Awesome job man
Awesome!!! Great info... And Look at that Drum set!! You keep getting cooler and cooler!!!
So i binged watched a bunch of your videos last night this one is pretty awesome it keep everything clean. I didn't even know you could use cat 5 like that. I will use this video again when I get to the lighting stage on my jeep build. Good job I enjoyed that video and learned alot
thanks man!
I do repairs for large chain body shops as in wire harness replacement and repairs, frame swaps ,diagnostics and programing and anything in between. I really appreciate the thought you put into this... we're supposed to return the cars to factory by every now and then we get stuff where the owner has added circuits with no direction at all lol. Those jobs are horrible . It can be really aggravating to try and get em back to whatever they had going on before the accident. Most times were missing the majority of whatever it was that they wired up so it gets outta hand quickly especially trying to do an estimate without replacement parts. Only thing I'd change is to solder any connections possible and use heart shrink with the glue inside to completely seal the joint. With the mud, water and dirt intrusion while out wheeling it don't take much to get the crusties and that can wreak havoc and possibly ruin components and start fires but having said all that I want enthused about doing any of this on my xj lol. Good work bro. I really though I'd be working on my rig all the time but she just sits there haha. My lift kit isn't here yet and neither is the radiator and steering column so I can't really dive it yet... I'm hoping when the parts get here I'll overcome the dread of working on my own stuff ... the thought of being out wheeling should get me going...I hope
Great video! It took all the worry out of my project!
I figured i'd finally ad a comment on something, cuz you (guys) do ALOT of cool projects, and helped a lot of us out on our Jeep projects ... or DIY fixes. End up here a lot when i'm trying to fix my Cherokee myself ... to save me a ton of money. To name only a couple, "Death Wobble" and Ball Joints. Great stuff guys.... now i'll go find the Dana 30 truss video, cuz I like my Dana 30 to!
Ha, thanks! Leave more comments!
awesome videos! i love your channel. thanks so much for taking time to do this
Wow, I never thought of using cat5 or cat6 cable for automotive applications.. Neat idea!
why not just pull a entire dash harness with like 100 wires at the scrap yard for like 20 bucks you get tons of fancy colors too !
USB protocol has a fundamental distance limit of only about 16 feet
yes thats true, but if your going through the trouble of doing that you might as well just use the extension cable that came with the extender. a side note, i think usb 3 might have a longer limit too
oh i see it uses cat5, thats cool
The number one reason you might use network cable is for the shielded variety. Works super well for sensor data lines.
I think this is my favorite video, at least the one that I found most helpful
This is probably the best video for info. Thank you boss
Great video, Matt. You just simplified my next project.
Thanks for sharing this information! I've been thinking about building something very similar to this for my JK - you've given me some great ideas! Keep em' coming! :)
Great video! I will be building one of these blocks for my 95 xj. Keep up the great work on your channel.
I gotta do something like this for my old Toyota. Got a whole mess of stuff connected to my battery and using the IGN lead as a trigger. Been wanting to put it on a relay with multiple leads for a long time. Good video brother. I especially like the CATV idea.
I followed this video and successfully built my own fuse/relay box for my YJ. Very similar to BleepinJeep but I think my end product is quite a bit better. I got two fuse boxes out of early 90's XJs and was able to disassemble them with minimal damage, hence no need for epoxy. I was able to re-arrange the existing cables into a different configuration that gives me 7 relay outputs that are each individually controlled. Additionally, they wiring harnesses I removed provided plenty of good wire for both outputs and the control wires. I looked at CAT 5 but found that re-using the harness wires made a far more durable end product. Only downside is that all of this took an insane amount of time and effort.
Awesome video, one of the best I have viewed. Thank you so much for for this!
your smart, right on man thats for the video. ive tryed alot to figure out how to do something along these lines.
Great video Matt. I applaud your willingness to share your knowledge with us DIY'ers on limited budgets. To the critics of using CAT5 cable....look around and you can find stranded core CAT5 cables. Stranded CAT5 is usually used for connecting laptops to a network. They may be more expensive but it might help them sleep better. Just saying.
Sir, you are the Mr. Rogers of off road. Please take as the compliment it's intended to be. You just kinda sound, and talk like him.
Like a spod, or blue seas block, only with more relays.. Really awesome idea, never thought of that before..
Chris Hundley yep, much cheaper as well.
Here's an idea to consider.. install a resetable 100amp breaker in front of it... BleepinJeep
Great video, very easy to follow along, i like it
thank you I learned a lot watching your videos
I never even thought of using a pre-made fuseholder. when i replace my glass-tube holder, i'm going to use one of these, and make it hinge down from under the dash instead of being way up and impossible to get to. This is a REAL life hack.
Pro tip: When wiring using multiple colors, do so in the rainbow order that we all know (red, orange, yellow, green, blue, purple).
that was so cool thanks man really helped out
Hell of good stuff!
Video should also be good for how to add fuses/relays to your existing fuse box (options your vehicle didn't come with but could have had from the factory) just have to find a donor block for parts....
That's what I want to do on my pickups....
I agree, very well done video, good job!! I wouldn't have thought of the grease and epoxy... XP
Picked up 3 of these yesterday to do this.
Thanks brother for sharing your knowledge.. blees you more😘.
you are so freakin awesome. I have two jeep relay boxes. I am getting ready to do this to my Nissan d21.
Excellent video "write-up" gonna have to change my hot mess of wires and switches over to this soon! I have too many accessories that are problematic because of the wiring mess i made.
really good info! thanks!
4 years later a few updates: you can also get this in grand cherokees - same fuse box. Also, with Cat 7 being out, it's considerably thicker than cat 5 or 6, so I would use that instead. Last but not least, use a cat 6-7 punchdown keystone jack to terminate the wires coming out of the fuse box, and one for the switch box... then just connect them with a cat 7 cable without having to strip the ends down. Or at least that's my plan. :D
You are looking at about half an amp per pair of wires in that cat 5 cable, hope that's enough to turn on those relays...
What year grand cherokee?
@@Aximili55 not sure if you have found the answer yet, but 1992-1998 seem to have this panel.
Neat lightbar. I jus bought one myself a few days ago. Just need some nice weather since I don't have a garage to install.
Good video!
Great video write up. One suggestion you can get wiring snake that has 22 gauge wire in it with a shielded and insulated jacket. Basically the same thing as the cat 5 cable but larger gauge designed for doing audio video patch panels for broadcast work and stage microphone wiring. The stuff is more expensive but a length long enough to reach from the relay box to the cab probably wouldn’t cost more than 20$. Pro audio multicore wire.
Good re-use of parts there! works for a good tidy install.
If you do a search for "mini-blade busbar terminals" you can actually buy the proper crimps that should click back into the slots saving you epoxying them in place!
I'd also be careful with the amp rating of the white connector block you use as this size are normally around 10-15A.
Ive spent about 4 hours trying to find these online you are a god damn life saver
The terminals aren't what breaks. It's the plastic tabs in the block. I managed to only break one or two. The metal tabs are easy to reuse, but it sure would be nice to have had a pile of loose, new ones.
Can you put up some part numbers and where you got them?
an addition I would make, before putting the epoxy on the terminals I would slide the relays into place to make double sure each spade terminal is lined up as best as possible, would make later sliding them on and off a lot easier.
I plan on making a few minor adjustments :)
excellent, will be doing this, no more worries about electrical fires burning mine to the ground..
Just built me one it is great good vid
Great video thanks!!
another awesome video! thank you sir, keep up the great work, you make me want to do all this stuff to my 99' 4x4HO sport! I have managed to fix all damaged bushings and linkage, fix all leaks, has all new fluids, just need to throw fresh springs, shocks, maybe go long arm... dude do you think you could do an xj with a machine gun turret top for observation etc? maybe even a fake .50 caliber MG?
THAT would be SICK!
I tried using the CAT5 however the relays I used pulled more power than it could handle. Flipped a switch and had a immediate small fire. Ended up using 18 AWG to power the relays. I really liked the idea though.
great vids been subscribed forever!!!! love everything you do!!!!!! QUESTIONS!!!! Can i wire the battery wires to the relay first before the fuse or it doesn't matter? I'm doing an ls swap in my k10 and want to run between 4-8 relays for indiviual components versus the standard 2relays.....
Great Video ! ! ! !
I've wired 3 of these and everytime I watch this as a refresher
Depending on the length and location of the red "hot or positive" wire connection to the battery, a fusible link near the battery might be a good protection against a possible chafe or damage to what is basically an unfused wire otherwise. It is an extra step, but it could save a fire and/or damage to valuable electrical parts.
Automotive breaker same concept as breaker box it the house...
powerwerx.com/resettable-circuit-breaker-cooper-bussmann?gclid=CjwKCAjw6szOBRAFEiwAwzixBXnDScCDraL2_3BSBTrDtSVn1MzuCIW5Me_TRp2Hik4eXxgckXt3qhoCVKAQAvD_BwE
Ok I like what you are doing and how you are doing it ,I envy you in your patience and delivery and kindness to all of us by sharing what you have done ,if like me yo will do it just to prove you can bypass the check out counter.I hit that like button and subbed your channel , I rarely do that .What you have in patience I make up for in fowl language and tenacity. I usually wont stop until I break it or fix it .
Where you ran the single 12v supply wire along each fuse connector I 'll do the same ,but instead I want to bypass the fuses or the need for them altogether , by soldering a jumper across each given fuse connection point to the 12v supply wire and onto whatever designated wire or point the fuse was intended to protect . No worries about current draw ,my old jeep id pretty much no frills bare boned almost to the point of a Willis GI issue. . Im not asking for any advice or other freebie time soaking stuff ,besides ' Im much too hard headed for that , but if you read this in the next 24hrs and can find your old wire clippings I sure could use the colors and stripes from the old ones theres not much I can do seeing how packed in there they all are and the harness wont let me peak at the ones Ive got . Stay safe God Bless ,wear your condom and wash your hands you might have popcorn for supper never can tell these days
Matt, maybe just one suggestion. I would put a high amp fuse on the supply wire to the entire box. One used on a stereo amplifier would work well and could also be found at the junkyard. They can easily carry 200 amps no problem.
Wow!! Thanx!!! You really got down!!!
that's a great idea for my Tenn plates I was wondering what to do with them
Genius thought.
Great video! This will help me out a lot. Only part Im confused with is since my switches arent all in one spot, that the cat5 wire wont work well for me unless im missing something.
You can make a similar relay/fuse box using one from a dodge neon. Dodge neon is smaller and has six relays.
I suppose since you're a Jeep guy dielectric grease is ideal. I preferably would use the (yellow) clips. It's less messy. Also That's really cool you salvage parts like the fuse block and license plate as the switch panel. Less waste.
AWESOME PROJECT! I really enjoyed working on this. Learned a lot. My questions are what kind of accessories would be appropriate to run on fused wires only (no relay)? What accessories would require such high amp maxi fuses? And could you give a list of examples of what could be ran off of the relays/fuses besides lights? Thanks again. Great video!
You could run your CB to it .... that's all I can come up with at the moment. OH! one of them back country Electric Fridges. A Cigarette lighter style plug, which is great for blowing up floaty toys once ya get to a lake.
This is great
Good job
hey awesome video!!! just scratching the surface of wiring myself. I'm just wondering if this set up would work for power locks?
I did this using the existing wires. took a bit of time to tear apart and sort it out. then I ran a large fused wire from the battery to the back seat. since I am using mostly for lights I ran all to the back seat. then removed the jack and used the holder to keep the box in place. it is out of the mud and weather and if it gets wet I am sure I have far bigger issues.
Most awesome!
Real informative. new relay and fuse box. This new relay and fuse box can go under rear seat too right.
Very good project. For me, I'd want to get a source on those female terminals that also have the tiny blade to retain them into the fuse box for the relays vs. the epoxy method. They must be available however, could be you have to buy them in minimum 500 or 1,000 piece lots. LOL.
sick I'm going to build one soon
Thank you now I can clean up my battery terminals and make it look better!
ok thx, befor i had to replace the cpu it was running bout 180 unless i was off roading it would go up a little so i would run heater and it would go back down to 180 or 185 so now its running hotter wasnt used to it thx im replaceing thermostat and housing do you fecomend a 180 thermostat or 195? thx and i watch all your vids if i wanna do something to my jeep your vids are my go to sorce.
Always straight to the point love these videos you do a great job! Keep it up. Were did you post those diagrams by the way.
bleepinjeep Thanks
Awesome thank you.
Great idea!!! Only thing I would caution you about is the CAT5, the 4 pair (8 wires) are solid wire. Problem is in cars that vibrate solid wires tend to break (shear) from the movement quicker than stranded wire. That's why vehicles use stranded wires. Just a thought for future reference. I really thought this was a GREAT IDEA!!
Gliden07 glad you like it!
Cat5 can carry power. It's POE. Power Over Ethernet. It powers VOIP phones. And there are two types if Cat5 cable. The solid core wire that comes on huge spools and is meant for in the wall/ceiling installs and punch down termination. The patch cables you by to connect network devices are stranded cable.
Cat5 can carry power. It's POE. Power Over Ethernet. It powers VOIP phones. And there are two types if Cat5 cable. The solid core wire that comes on huge spools and is meant for in the wall/ceiling installs and punch down termination. The patch cables you by to connect network devices are stranded cable.
Excellent video!. My buddies low dollar jeep is not starting with the key (tried park and neutral. but you can jump the solenoid to start it. We believe the problem lies with the neutral safety switch (190 dollar part) which is out of the budget. Sound right to you? Our solution is likely a push button setup.(ignoring the obvious short comings of overriding the switch) WHAT DO YOU THINK? TIA
Really enjoy your videos, this one most. Watched it several times and have in hand my used fuse box. This is going to be a slow project but I do have an early question. Do you have any problems with engine heat on the Cat 5 switch cable?
I am planning on doing this as well. I have some experience with electrical but mostly I am a computer and networking hardware guy. I would look on craigslist or ebay for plenum cat 5e or maybe even cat6. You can of course get some from home depot. the plenum cable is rated for 75 degrees celsius and 300v. That should not over heat of you are just using it for a switch. the switch should just be sending a small spark to the relay if understand this all correctly. Don't mount the cable directly on the engine and you should be fine.
Another way to think about it: Many devices the go into point of sale systems or networking gear require POE (Power over Ethernet) Some of the devices these can power include The card swipes we use every day at the gas station and grocery stores. another big use is the piece of networking equimpnet which provides wifi such as when you see a wifi "box" mounted on the ceiling of an office, grocery store, etc. Those are often receiving power over ethernet cable. I would highly doubt that the amount of power an auto switch is using, is going to require more than that.
Sorry for the long explanation. Hope it helps!
Thanks!!
Hey Matt...i know this is an older video but still relevant ..... is there a reason to run the maxi fuses if I'm not gonna run any higher loads?? can i eliminate those wires altogether to clean it up more?? just rock lights and some led ditch lights.. the only thing i could see running thru it higher is maybe an on/off for winch..
If the switches in the cab are backlit, would the CAT5 cable be enough of a gauge to power that? - NVM i got it at the end lol
bleepinjeep The Maxi-fuses have two clips. If you pull up the yellow bracket, you find a plastic clip. Then on the metal connector itself there is a metal clip that needs to be pushed in. The maxi-fuse holder then slides out.
Would have been cool to put a female cat5 connector into the side of that powerblock module, then you could have just "plugged in" your cat5 cable! If all your switches are in one place, you could have put a 2nd female cat5 connector on the side of your switch module.
thank you, i am going to try this !
@24:18 for more Cat5 stuff
The problem with the RJ-45 connector is that it doesn't have any current carrying capacity. It's designed for signal voltages and currents in the milliamp (mA) range. Look at the wire fingers in a connector and ask how much current can really pass through a single point of contact on a 30AWG wire? Many relays draw up to 2 amps of current to operate the solenoid depending on the relay design. Others use only .5 amp. Be absolutely certain your connection can handle the power of the circuit it controls. Look at the headlamp switch that route all of the power through it for the headlamps. Even with those large blade type connectors, the plastic still melts because too much current is drawn through the switch. This is why relays are used but even relays use power and those circuits and their connections have to be capable of handling that too. Safety first or the Fire Department may pay you a visit.
Digikey sells connectors with locking tabs so you won't need to use epoxy.
14-16 AWG - www.digikey.com/product-detail/en/molex-llc/0192730008/WM6237-ND/2793739.
10-12 AWG - www.digikey.com/product-detail/en/te-connectivity-amp-connectors/180384-2/180384-2-ND/1131475
They are not the cheapest but they are of higher quality that the factory used than your run-of-the-mill auto parts stores cheap crap.
SN Interesting yes. Question would be how much current those relays use to enable the higher amperage or load. If he had that data, he'd also have an answer if all 8 fingers will carry all 8 relays current requirements without heating up and melting.
I too question the capabilties of cat 5 wire in this application. I will say i have successfully done many things others say wont work. The true test is to roll up your sleeves and do it. If it doesnt work bow your head and try again. I'll say most large power draws that require a large relay trip already have that wiring included. Example, a winch has a large power draw, and a huge relay, or solenoid. Most if not all electric winches have them in the case. So my guess is being the largest power draw he can use is 20 amps he should be ok.
I am in need of a Flux Capacitor. My issue is that I am using Synthetic Blinker fluid, and yes I use the directional type so I have the left and right Synthetic Blinker Fluid specific to the corresponding side. Are your Flux Capacitors comparable with and for this application? Thank You in advance for your response. BUT MOST IMPORTANTLY GREAT VIDEO. Wiring is one of my favorite things to do so this was right in my wheel house. Keep the videos coming. Yes I know this was from 2014 but I have been busy researching availability of a new left handed set of screw drivers.
also, for the power to the switches, you said "either a 12v source or direct to the battery." Does that mean if I want the switches powered independently if the vehicle is on or off that the wire goes directly to the battery along with the power cable that connects directly to the relay/fuse box? this is all fairly new to me...
Do you need a dedicated relay for each light or what ever you're wiring up? I've seen some relay/fuse blocks from "Painless Wiring" that have 7 fuses and only 1 relay...
Wow great