Boogie wagon take 2

Colibri · Post by **Colibri** » Sat Mar 12, 2016 11:32 pm

Cool, I'd love to see how you end up installing it. Roof real estate for me is at a premium with the cab marker lights up front Sirius antenna out back and the center mount ham.

Colibri · Post by **Colibri** » Tue Mar 15, 2016 7:57 pm

Okay! Started the first portion of the wiring today. Using MIL-W-22759/16 mil spec wire for everything, it's Tefzel insulated good to 300* and each individual copper strand is tin plated. It comes in any insulation color you want, as long as it's white lol. Therefore wire identification tags are a must. I'm using a BEE3+ heat shrink tubing thermal printer to label every wire then clear heat shrink over the tag. Instead of zip ties I'm using MIL-T-43435B lacing cord. Good to about the same temp as the wire and 50lb test. Every couple inches you tie a clove hitch followed by two half hitches to bundle the wires securely. Sheathing the bundles in Raychem DR-25 Heat shrink which is resistant to fuel, oil, and battery acid and good to 300* then sealing the ends of each bundle/harness with either a shrink boot and epoxy or adhesive lined heat shrink depending on location and connector style etc. Deutsch DTP and DT connectors for everything.

This first bundle is the power feed for the ham radio. Deutsch size 12 pins at the firewall connector to 10 gauge wire, all rated for 25 amps continuous. Down to a two position male DTP connector for the kenwood.

Post by **Pit Slave** » Tue Mar 15, 2016 9:34 pm

Very nice, I have piles of Tefzel, Kynar, TFE, PTFE, type of wire. Lots of it from aircraft, the rest of it laying around on spools! lol Have a drawer in my tool chest that cost an average of $100 a square inch in tools to do all the prep/crimping. I don't use standard wire strippers on the hi-rel assemblies, I have a heated no-nick wire stripper for that. Zero chance of a break from vibration. Wire assemblies/harnesses is one of my jobs. I plan on doing the entire truck one day, if I get the time that is, lol.

#crimpinainteasy

Sent from my XT1254 using Tapatalk

Colibri · Post by **Colibri** » Thu Mar 17, 2016 9:10 pm

You're a damn Renaissance man pit slave!

This is my first foray into wiring on this level but thus far I am really enjoying the process. The tools and materials were a huge up front investment for me but it seems well worth it. If you or any other knowledgable fellas here have any pointers or suggestions I'm all ears, I've only read about all this up until now but am eager to learn and do! Doing the entire truck would be fantastic, just incredibly expensive and time consuming lol. I'll probably do it piece by piece through the years as things need attention though.

Started work on the gps interior harness this afternoon. Going to cap off the nmea harness for now, but want to have it accessible if I need to network things in the future.

#crimpinainteasy
#^truth^

NovA ProspekT · Post by **NovA ProspekT** » Fri Mar 18, 2016 8:04 pm

Love your truck man!

I like where you mounted the GPS antenna, beats drilling a hole through your roof.

Maybe I missed it, did you mount your Bussman fuse block yet? I'm about to order their RFRM(40-fuse, 10-relay), though I'm not sure where I am going to mount it yet. Right now I'm thinking of grabbing some sheet metal and making some kind of quick-detach/hinged mount somewhere near the stock fuse-box.

Colibri · Post by **Colibri** » Fri Mar 18, 2016 9:06 pm

Thanks man! I haven't mounted my block yet, I've been having trouble placing it in the engine bay. It's very tight over by the tipm. Current thinking is that I'll place it over by the airbox. Probably make some sort of sheet metal bracket as well. You're getting the big boy! That thing won't be easy to find a place for. Definitely do a write up when you get around to it!

NovA ProspekT · Post by **NovA ProspekT** » Sat Mar 19, 2016 12:27 pm

Yeah, I'll definitely do a good write-up on the Bussmann unit(and the mount), there doesn't seem to be much info on them. Might have to fit it over by the airbox, though I'd prefer to keep it near the stock box for ease of wiring.

2wagons1driveway · Post by **2wagons1driveway** » Sat Mar 19, 2016 8:27 pm

Damn them are big wires ! Looks like your going all 26th century and running fibre optic for everything

Sent from Canada

Colibri · Post by **Colibri** » Fri Apr 01, 2016 10:01 am

Done with all the in cab wire harness construction and moving on to the air locker plumbing next.

05PWrockcrawler · Post by **05PWrockcrawler** » Fri Apr 01, 2016 10:36 am

Fancy fancy

Sent from my iPhone using Tapatalk/hopefully somewhere Offroad!

2wagons1driveway · Post by **2wagons1driveway** » Fri Apr 01, 2016 12:59 pm

Sweet

Sent from Canada

Colibri · Post by **Colibri** » Fri Apr 15, 2016 4:50 pm

Just put a deposit on a rollcage kit for the wagon! Should be bent up and notched and shipped in about a month. Here are some pics of the cage kit installed in another 3rd gen crew cab

Will · Post by **Will** » Fri Apr 15, 2016 7:01 pm

That's just fucking awesome!

2wagons1driveway · Post by **2wagons1driveway** » Fri Apr 15, 2016 9:01 pm

Hey Tim stoked you actually pulled the trigger! What are these mounts everyone is speaking of?!?

Sent from Canada

Stickman · Post by **Stickman** » Sat Apr 16, 2016 1:24 am

A really cleanly installed cage would be a very cool addition, even to a daily driver. Looking forward to seeing this in yours.

Colibri · Post by **Colibri** » Sat Apr 16, 2016 2:15 am

Thanks guys! Debating now which seats to go with, I'm leaning towards the prp enduro tied into the cage.

Lee, maybe you're referring to the body mounts for the cab? When you tie the cage to the body and the frame you need to either rubber bushing mount the cage or use solid body mounts so you don't cause problems between the two. Not sure which way I'll go with the cage mounts just yet

Reloaderguy · Post by **Reloaderguy** » Sat Apr 16, 2016 9:15 am

I do not need a cage...I do not need a cage...I do not need a cage. La la la la laaaaa.

Awesome!

2wagons1driveway · Post by **2wagons1driveway** » Sat Apr 16, 2016 9:38 pm

Lol ok that makes sense!!!

Sent from Canada

adeluca73 · Post by **adeluca73** » Thu May 05, 2016 5:46 pm

Just finished reading the entire build out--took me a few days here and there, but holy F man, that's some impressive work, you must be a mechanic in your other life....

Will · Post by **Will** » Thu May 05, 2016 6:59 pm

The factory cab mounts must go, they're on my list.

Colibri · Post by **Colibri** » Thu May 05, 2016 9:02 pm

Hahaha thanks for the kind words! I actually am ASE master certified lol. Doesn't mean as much as it should though.

Will, go get some hockey pucks and a drill man! Save your cab corners from further damage

NovA ProspekT · Post by **NovA ProspekT** » Fri May 06, 2016 1:17 am

Bro, that cage...

Is there a company making these?

Can't wait to see what it looks like when everything is finished. Safety equipment may not be sexy, but nothing's more important.

Will · Post by **Will** » Fri May 06, 2016 5:44 am

Colibri wrote:Hahaha thanks for the kind words! I actually am ASE master certified lol. Doesn't mean as much as it should though.

Will, go get some hockey pucks and a drill man! Save your cab corners from further damage

Hockey puck? Man, I'm in Florida, never even seen a hockey puck! Haha

nts007 · Post by **nts007** » Fri May 06, 2016 9:02 am

How many do you want. I have a shed full

Will · Post by **Will** » Fri May 06, 2016 9:09 am

I can order them, just saying it's not like I can run to the store and pick them up. Never would have thought of it.

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