Locker Bypass Improvements

[Retired BLM Rig]

I've been making some changes to the Locker Bypass. There's already a few of these out in the wild with some good feedback.

The first improvement is a control box that's 30% smaller giving it some better mounting options.

The new box is square instead of rectangular making it symmetrical so the box can be rotated 90º on the flanged base to provide improved wire harness routing options. The supplier is CNC machining the cutout for the bulkhead connector for me, which gives it better fit and finish.

It's still a rugged, heavy duty waterproof enclosure. There's a silicone gasket that fits in the groove of the base.

Once the gasket is pushed to the bottom of the groove it's barely noticeable.

The 12 pin connector I use is also rated for outdoor, waterproof applications. There was one person that had some water get inside the box. The only way I can imagine that it got in there would be if the electrical connector was facing up and rain water was allowed to pool on the connector and then as the enclosure was exposed to expansion and contraction, heating and cooling cycles in the engine compartment, some moisture was drawn in around the wires. So word to the wise, try to keep the electrical connector at a downward angle to shed water rather than collect it. I also pressure test each unit once it's assembled. If anyone else has had any issues like this, please let me know so I can address it and maintain QC.

Previously I was using two different control boxes for 3rd and 4th gen trucks, but now with this smaller enclosure... one size fits all.

[AceMan]

test test

[Retired BLM Rig]

One of the ways I was able to downsize the control box was to downsize the components inside the box. The relays on the left are the original ISO style that Morgan was using and the ones on the right are what I'm currently using. They are the same brand and type found in your factory fusebox and have the same amp rating.

Comparing the difference between Mini and Micro relays.

Also Morgan's relays weren't easily replaceable, but now mine are.

Using smaller relays has made room for more components. Here's what the inside of the new "Full SmartBar Bypass" looks like.

Inside the new "Full SmartBar Bypass"

[Mule007]

Nice work Retired BLM rig