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Ideas to enclose and waterproof headlight relays?

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Old 10-29-2012, 08:35 PM
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Ideas to enclose and waterproof headlight relays?

I finally got my dash wire harness mess figured out by getting the H,L and G squared away on the headlights - I put in two relays per the attached picture and they are placed on the right side interior fender along the route of the normal headlight harness lead. Does anyone have any suggestion how I can enclose these to waterproof them - 'box' would need to be about 6 inches long (to wrap in the circuit breakers) 2 inches wide and maybe an inch high. Love to have a snap lock, waterproof, black box and I'll put the holes in each end to receive wires. Been looking around on web but hard to find exactly what I need without buying 10,000 of them from China. Any ideas?

[IMG]http://www.ford-trucks.com/forums/picture.php?albumid=31078&pictureid=113
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Old 10-29-2012, 08:37 PM
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Try again on pic.....

....................
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Old 10-29-2012, 08:40 PM
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another try at pic

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Old 10-29-2012, 08:54 PM
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Now that I am an expert on posting pictures, here is the wiring diagram i used which maybe will be helpful to someone else.....everyone says use relays but darn if I could find a how-to on this site........

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Old 10-29-2012, 09:18 PM
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Nice work, glad you figured it out. Any way you can put these connections back up under the dash, I know it means redoing them but now you know how it won't take as long. Just a suggestion.

On the other hand, you could glue up a box out of plexi or something but to me it seems like more work than running longer wires and putting them under the dash!

Take my opinion, I'm not using it!
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Old 10-29-2012, 09:25 PM
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Dash thought

Hmmm, thanks - I was so focused on the relays and the how-to I didn't consider 'where' until after. From what I could read, the real purists would say to have those relays as physically close to the battery as possible but would not be an issue to move the mountain under the dash - now that I finally understand the wiring I feel like the mountain is on wheels and would be no big deal to move (once Ms. Sandy passes by!)
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Old 10-29-2012, 10:36 PM
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You can put them in an electronics project box if you don't want to relocate them. They come in different sizes and are essentially a plastic box with a lid. Just drill holes for the wires in the side and put a dab of RTV or use grommets where the wires go in. For your specific case with the two relays, relocating them would probably be the cleanest.
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Old 10-29-2012, 10:51 PM
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Mine are approximately where yours are,but on the inside drivers fender well. I also have at that location an auxiliary fuse panel, a marine grade Blue Sea one from West Marine.Also there is horn relay I installed, and a relay for my auxiliary lights.Banking the fuse panel and all the relays together seems easiest to me, and it looks very clean in my opinion.It better, I'm an electrician. When I did the work, I made sure to use the superior quality(vs. Autozone) Bosch relays. They were German made at that time,prolly not anymore.They are quite weather-proof.

Those relays will be fine,as located,no real need to move them. We have very wet winters here, not like Gary , but still 50- 80 inches from about Oct. to April,never had a problem with any of the relays
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Old 10-30-2012, 01:52 PM
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I'm hoping that the relays are weather proof enough on their own. Mounted mine in the same general area.
[IMG][/IMG]
Here is an article on using relays from FTE articles/specs by John Niolon
Old Trucks: Using Relays to Control High Amperage Circuits .: Articles
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Old 10-30-2012, 05:37 PM
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Shrink Tubes!

Ah - you sent me a subliminal message to shrink tube the leads! I had not done that. You have a tight set up there - looks great! My relays did not have mounts so right now they are flopping around....

I am going to get a box from here.....

Project Boxes | AllElectronics.com

Looks like a real good selection.

Many Thanks!
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Old 10-31-2012, 10:34 AM
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Water won't bother the relays if you turn them upright (terminals on the bottom). You can then work to weatherproof the wire terminals. Dielectric grease is great to help prevent corrosion.
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