Down to the Wire

I have been getting a start on the jeep's wiring. Here is what I have done so far.

Here is the wiring for the radio door circuit. It works like a charm, but pulls too much current for the hobby battery.

Here is the jeep wired up:

The engine is wired and turns over with the key.

Here is the in-dash wiring.

I sealed the steering wheel hole with an old dirtbike tube and some silicone.

The rear lights are installed.

I had a mechanic come test out my steering wheel installation, things seemed to check out alright.

Here is my current to do list. There are way too many small things for my to remember, so I am just going to start writing them down here. I imagine that new items will come up faster than i can cross them off.

Currently the jeep is filled with all kinds of junk.

Hopefully tomorrow I'll have a video of the thing running. I will definitely have it running by the weekend.

Electric Slide

I am making a way cool component in the dash. Basically it will be an electrically operated door that covers the radio door to prevent theft. The logic is: when the radio is on, the door will open and stay open. When the radio is off the door will close and stay closed.

I have also gathered the components:

1 Solenoid: to lock the door

1 300rpm reversible motor: to move the rack and pinion back and forth

1 rack and corresponding spur gear: this is the core component here, converts rotational motion to linear motion, a rack is like an unrolled gear

2 micro roller switches: for shutting off the circuit

3 SPDT relays: for motor directional changes and ignition switching

1 SPDT relay: for solenoid that locks door

2 Drawer sliders: for the door to slide on

1 Fuse block: for when my crappy wiring shorts out so the jeep doesn't burn down

4 colors of auto wire: for making nests

Tons of connectors and wiring harness connectors.

I drew up a schematic of the electronics required to do this:

Here are some of the goodies:

Micro roller switches. These shut down the circuit when the door has traversed its extents. The circuit will then wait for an interrupt from the opposite signal.

These are the ball bearing sliders the door will operate on.

Here is a prototype of the motor/switching circuit.

I am testing the video capabilities here. Once the circuit and everything is completed, I'll put a demo video up of its operation.

d a s h | DESIGN

So am am designing the dash. I think my design is complete, I just have to make final measurements regarding the sizes of some of the switches that i plan on using. Click on the picture to really see what is going on!

I am missing the bolt hole positions and I may want to play with the grab bar a bit more. This is what it will approximately look like though.

The black rectangle to the right of the gauge cluster is the stereo door. The stereo will have a door that automatically opens when the radio is on and closes when the jeep is off. It is kind of a big deal.

Kick Some Assembly

So you can see in these pictures that progress is being made. There are still a lot of loose ends to be fixed, but the main things in the pipeline are:

Wiring the whole jeep, running fuel lines, brake lines, etc.

Dash: This is part of wiring,but also involves a lot of fabrication.

Paint: I have to paint the rollcage, fuel rack, bumpers, fuel cans, dash, etc.

The pedals are installed, I painted all the hardware gloss black.

Seat risers. Oh I sold the nasty bucket seats these came with for $25.

The steering wheel got more of a satin black treatment, as that was closer to the original color.

Here is what the jeep is looking like these days.

Engine shots, it needs a good rinse from all the crazy sanding dust.

Oh, I finally have the steering wheel installed!

Steering knuckle.

Engrave Danger

So I found a company that makes switch panels. Check this out, you go on their website, download their software and get to designing.

Here is my design screen:

There is a little "$" button in the software you can click at any time and get this:

############################################################
############################################################
Pricing for the file:
C:\Documents and Settings\xxxxxxx\My Documents\My_Stuff\jeeeeep\dash\dashRoughDraft.fpd

Based on price list of: Front Panel Express, LLC
Price list date: December 1st, 2007

Type | Position | Remarks | Price
-------------+---------------+--------------------------------------+-----------
Other | ------------- | Preparing/finishing | $14.38
Drill hole | 167.64/113.03 | Diameter: 3.3750" | $3.69
Drill hole | 245.11/104.14 | Diameter: 2.0625" | $2.30
Drill hole | 310.99/101.44 | Diameter: 2.0625" | $2.30
Drill hole | 216.85/49.21 | Diameter: 2.0625" | $2.30
Drill hole | 277.65/49.05 | Diameter: 2.0625" | $2.30
Drill hole | 339.72/48.89 | Diameter: 2.0625" | $2.30
Drill hole | 79.85/87.47 | Diameter: 0.5000" | $0.64
Drill hole | 48.10/53.18 | Diameter: 0.5000" | $0.64
Drill hole | 119.22/143.35 | Diameter: 0.5000" | $0.64
Drill hole | 214.47/144.62 | Diameter: 0.5000" | $0.64
Drill hole | 79.85/53.18 | Diameter: 0.5000" | $0.64
Drill hole | 46.83/87.47 | Diameter: 0.5000" | $0.64
Drill hole | 8.89/8.89 | Diameter: 0.2500" | $0.37
Drill hole | 8.73/168.75 | Diameter: 0.2500" | $0.37
Drill hole | 8.89/91.44 | Diameter: 0.2500" | $0.37
Drill hole | 130.81/170.18 | Diameter: 0.2500" | $0.37
Drill hole | 252.57/167.48 | Diameter: 0.2500" | $0.37
Drill hole | 382.11/168.75 | Diameter: 0.2500" | $0.37
Drill hole | 384.33/87.15 | Diameter: 0.2500" | $0.37
Drill hole | 381.79/8.41 | Diameter: 0.2500" | $0.37
Drill hole | 253.52/5.87 | Diameter: 0.2500" | $0.37
Drill hole | 132.87/7.14 | Diameter: 0.2500" | $0.37
Engraving | 71.12/76.20 | Winch | $1.20
Engraving | 30.48/76.20 | Sol Brake | $1.92
Engraving | 30.48/41.91 | Int Lights | $1.73
Engraving | 69.85/40.64 | Stereo | $1.44
Engr. rect. | 62.23/63.50 | 3.0000" x 3.5000" Width: 0.0236" | $2.02
Engr. rect. | 194.31/88.90 | 13.9000" x 5.8000" Width: 0.0236" | $5.70
Other | ------------- | Engraving in-filling | $17.57
Other | ------------- | Multi-color supplement (2 colors) | $4.03
Other | ------------- | 2 Tool change(s) | $2.56
--------------------------------------------------------------------------------
Total: $75.28

Amount | 5-9 pieces | 10-19 pieces | 20-29 pieces | from 30 pieces
---------+------------+--------------+--------------+---------------
Discount | 5.0% | 10.0% | 15.0% |
Price | $71.52 | $67.75 | $63.99 | on request

The price is without sales tax and shipping charges.

In our constant effort to improve our products and services we reserve
the right to change specifications and prices without notice.
############################################################
############################################################

That's right! The price of the very thing you just designed! Then you click order panel and the software submits the order to them and then you check out, pay your price for the panel, pay the shipping and then you get an awesome panel.

Here is their website:
http://www.frontpanelexpress.com/

Here are some shots of their work:
http://www.frontpanelexpress.com/en/showcase/front-panels.html

Anyways, I am very glad I found these guys, they have lots of colors to choose from for a base metal and then lots of epoxy fill in colors for the etching.

Here is what the dash will look like with my proposed panel (one of several):

Oh, did I mention that I cut the dash out with a circular saw? 1/8" diamond plate. I then cleaned it up with a wire wheel, some dawn, wire brushes and stuff. Next I'll hit it with a rust killer, then do some cutting on it, then do some big holes then some final grinding.

Diamondplate texture:

I also got the gauges in the mail! Steering column "cluster"

Speedometer cluster, goes in panel.

Beautiful

Dash Mock-Up

I went to Kinko's and had them print out the dash schematic that I am working on in Google Sketch Up. They printed it actual size so that I could "play drive" in the jeep to see how I want the dash.

Currently, I think the stereo is too far and the modular switch panel is a little too large. So I will make the panel smaller and see if I can squeeze the radio over. I also need to position the wipers, heater control, and the light switch.

I am going to move some switches and then focus on where I am putting some of the indicator lights on the dash, then I should have everything I want. Hopefully I'll finish designing by the end of tomorrow and can start fabrication by the middle of the week.

Design

This is the current dash design. I put in the gauges and properly colored the diamond plate. Not sure what colors to make the switch panel or radio door (I am thinking like a brushed aluminum). Also I added the speakers. I am still making fine tunings to the adjustment. I will next be printing this out at kinkos and then playing with it on the real jeep, making final changes.

Dashing Dashes

Here is the current dash, I am giving it a face lift since I have put so much work into everything else.




Here are the gauges I have bought:

Vaccum:


Oil Pressure:


Water Temp:


Voltage:


Fuel Level:


Speedometer:


Tachometer:


Clock:


Here is a switch to control the brake solenoid:




I am going to set the gauges in a a satin black diamond plate dash. I need to figure out how I am going to be placing the gauges, switches, and indicator lights in the dash. It is a big design task and I think I am up for it.

I have done some footwork to see what others have done:
http://www.manoian.net/jeep/custom_dash.html

http://media.photobucket.com/image/jeep%20dash%20cj5/silvergoat_photo/oldwheelinpics008.jpg

Look at the pictures in this thread (there are 4 pages):
http://www.jeepforum.com/forum/f8/custom-dash-ideas-659008/

And here are some of my own personal designs (right now I am focusing on the gauge cluster). I definitely want a removable switch panel where all the indicator lights and such will be. That way it is easy to add new controls. I am not sure where to put the clock, whether or not I want the gauges angled towards the driver, what I should do about a glove box, lock box, stereo (I am kicking around some ideas). Oh, and ignore the skull thing. The thing above the skull is the grab bar.

V1:

V2:

V3:

Here is my most recent design. I am going with smaller speakers, and am thinking about putting the clock by the steering wheel. There will also be a monster glovebox, which will house the stereo receiver, a CB, and just a general storage compartment. I am thinking the stereo/cb area will need a door that is easy to use and can stay open while driving. A rack and pinion type linear drive operating a sliding door would be awesome. I do like the smaller speakers.

V4:

Here is the plan. Continue piecing together the jeep. Get the pedals, steering wheel and driver's seat installed. Then make a cardboard dash and pretend to drive and operate controls. Mark where stuff should go with a sharpie. Make modifications with a different color. Update design. Fabricate. Paint. Install.

Also, I am open to your ideas and suggestions.