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View Full Version : Just a lit-tle bit tighter ... Oh DANG IT!


bikerjoe
04-17-2007, 11:34 PM
So it was time to install the left battery box and the cables. I worked all day and began the installation when the calls stopped coming. At 6:30 PM I began to figure out where everything should go, what cables and terminal ends I would use and so forth. Things went smoothly and I was nearly done at 1:30 AM this morning when, perhaps in a moment of fatigue, I snapped the bake-a-lite body of one of my relays! DANG those things are brittle! Well, that wouldn't have been so tragic, except that my bed was up in the air and a customer's bike was mounted on it!

http://i92.photobucket.com/albums/l4/20Dman/bikeup1-C.jpg

The truck was in my shop, and it was too tall to pull outside, so I had NO choice but to stay up and figure out a way to repair the damage. I scrounged around my pile of "junk" in the garage until I came up with four new matching relays, and then I had to figure out what WARN had in mind when they built the cluster of relays in the original controller.

After much study, a few paper drawings and the use of some jumper cables, I figured out that tripping relays 1 and 3 would send power up the F1 wire and connect F2 and F3 together, while tripping relays 2 and 4 would send power up F2 and connect F1 and F3. It has something to do with reversing the polarity, but I never really understood it completely.

Another two hours and I came up with a suitable replacement relay bank:

http://i92.photobucket.com/albums/l4/20Dman/winchrelays2.jpg

It works! :rad:

Now to finish the battery cables and get things wrapped up in time to deliver the bike when the dealership opens at 8:00.

http://i92.photobucket.com/albums/l4/20Dman/batterycables4.jpg
http://i92.photobucket.com/albums/l4/20Dman/cableseals1.jpg
http://i92.photobucket.com/albums/l4/20Dman/batterycables2.jpg

I arrived on time and then headed home for some sleep when the phone began to ring! hey, business is business! I did another tow, and then another. Fortunately they were both headed intothe same area.

http://i92.photobucket.com/albums/l4/20Dman/twoonbed2-C.jpg

It is now 4;30 PM and I am headed for BED! I'll sleep twice tonight, to make up for last night! :snore:

stp57
04-18-2007, 12:36 AM
Man, that's some nice work! A clever place to store your relays. Is that a tool case?
Steve

bikerjoe
04-18-2007, 03:05 PM
Nope! It is a red plastic box that formerly housed my safety triangles.

bikerjoe
04-18-2007, 04:19 PM
I went to General Sheet Metal in Escondido, Ca. to have the boxes fabricatd. I couldn't find any standard tool boxes or "ammo" boxes the correct size. these boxes are 16 gauge galvanized steel, made specifically for the various things I will mount. there are six boxes total. the others are for the hydraulic pumps, the air compressor and so forth. (Not mounted ... yet):popcorn: