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How to wire dune buggy using relays
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tekan1
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Joined: November 23, 2010
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Location: virginia
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PostPosted: Mon Sep 17, 2018 7:16 pm    Post subject: How to wire dune buggy using relays Reply with quote

Hey gang,
Forgive my ignorance but I am in dire need of a wiring diagram for my dune buggy. I purchased the empi harness kit but want to add a better fuse box with relays for better protection from overload. Anyhow, how would I hook up my universal starter switch to power my gauges and the relay switch to the ford solenoid on the starter? I have a relay for my starter, oil cooler fan, lights, fuel pump and extra for accessory. Attached you will find the relay set up I have. Any tips or guidance would be so very much appreciated.
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Dale M.
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PostPosted: Mon Sep 17, 2018 8:02 pm    Post subject: Re: How to wire dune buggu using relays Reply with quote

Typical ... Universal 30/40 amp 5 terminal automotive relay...

Terminal 85 is 12+ to relay winding (may be switched off/on (control))
Terminal 86 is ground for relay winding.
Terminal 30 is movable contact in relay, may source either +12 volts or ground (function dependent).
Terminal 87 is "make" contact to 30 ("make" contact closes on operation of relay).
Terminal 87a is "break" contact to 30 ("break" contact opens on operation of relay)

Image may have been reduced in size. Click image to view fullscreen.


SPDT (Single Pole Double Throw) relay... This is most common and widely used but there are other variations for various other applications...

Create wiring diagram on how everything is wired, and put designations on relay positions so a year from now when troubleshooting you know what relay is what... This is where "build" notebook comes in handy to document a kit car...

Universal ignition switches are something like this....

BAT or BATT terminal got to battery (main 12 volt supply)
IG or IGN goes to coil and power a fuse panel...
ST or STR goes to starter solenoid.
AC or ACC is for "accessories" such as radio or whatever.

Switch is wired by terminal designation and not by physical position of switch...

Image may have been reduced in size. Click image to view fullscreen.


Designation may be abbreviated somewhat different depending on source of switch (manufacture) but this general concept of how universal ignition switch is wired..

For electric fuel pump, I recommend this controller ...

http://revolutionelectronics.com/Fuel_Pump.html

Dale
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"Kellison Sand Piper Roadster" For Street & Show.
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All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...


Last edited by Dale M. on Wed Sep 19, 2018 11:33 am; edited 1 time in total
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tekan1
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Joined: November 23, 2010
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Location: virginia
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PostPosted: Tue Sep 18, 2018 7:51 pm    Post subject: Re: How to wire dune buggu using relays Reply with quote

Thank you for the valuable information. This weekend I will write out the plan and use your recommendations. Just nervous for I have never wired from scratch before and would hate to burn my baby up
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wheel607
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PostPosted: Wed Sep 19, 2018 7:12 am    Post subject: Re: How to wire dune buggu using relays Reply with quote

tekan1 wrote:
Thank you for the valuable information. This weekend I will write out the plan and use your recommendations. Just nervous for I have never wired from scratch before and would hate to burn my baby up


Dale has given you the right diagram....at least it is the same as my Cibie NOS 04-00-02Y 30Amp relay diagram .
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northernbody
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PostPosted: Sun Sep 23, 2018 6:33 am    Post subject: Re: How to wire dune buggy using relays Reply with quote

Hey, tekan1,

If I may, I would like to suggest a few hints to help reliability:

- Try to give a radius to wires, when you bend them. The wires with a sharp radius, like on your picture, will not last very long. Strands will break inside insulation and you will be chasing ghosts. A radius of 3-5 times the diameter of the wire is a minimum.

- Make sure the insulation is either crimped in the terminal or covered with a heat shrink, like you did for the red wires, not like the yellow ones. Heat shrink will also keep the moisture out.

- Make sure insulation is intact all all along the wires, unlike one of the white wires, and even ground wires. Copper corrodes fast and can be hard to troubleshoot.

- If possible, try to leave a small excess wire at each terminal (1/4”) so you could replace a terminal without replacing the whole wire.

- At this type of amperage, relays are normally not required but if you are going to use them, you can use smaller wiring and smaller rating switches for the actuation curcuit and have more switch options.

I hope this helps,

northernbody
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Alain
Mirabel, Qc
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northernbody
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Joined: November 14, 2015
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PostPosted: Sun Sep 23, 2018 6:34 am    Post subject: Re: How to wire dune buggy using relays Reply with quote

Hey, tekan1,

If I may, I would like to suggest a few hints to help reliability:

- Try to give a radius to wires, when you bend them. The wires with a sharp radius, like on your picture, will not last very long. Strands will break inside insulation and you will be chasing ghosts. A radius of 3-5 times the diameter of the wire is a minimum.

- Make sure the insulation is either crimped in the terminal or covered with a heat shrink, like you did for the red wires, not like the yellow ones. Heat shrink will also keep the moisture out.

- Make sure insulation is intact all all along the wires, unlike one of the white wires, and even ground wires. Copper corrodes fast and can be hard to troubleshoot.

- If possible, try to leave a small excess wire at each terminal (1/4”) so you could replace a terminal without replacing the whole wire.

- At this type of amperage, relays are normally not required but if you are going to use them, you can use smaller wiring and smaller rating switches for the actuation curcuit and have more switch options.

I hope this helps,

northernbody
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Alain
Mirabel, Qc
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