Building Homer (2005 TJ Build Thread)

[FarFire70]

Had an issue when I first tested wiring up the amp with the set-screws cutting through the wires. I probably went a little heavy-handed with the screw driver, but I didn't want the wires working themselves loose.

Either way, this is gross:

So I picked up a ferrule crimp end kit. My first time learning that these exist, but makes sense as a product/tool.

I went with this kit because it claims to be copper which I liked:

https://www.amazon.com/dp/B0CT5F94XB?tag=wranglerorg-20

This one gives a 6-sided crimp. Other ferrules offer a 4-sided/square crimp. New tool into my inventory (came with the kit):

And boom:

The plastic end slips over the wire insulator. I added heat shrink for added protection & strength.

I also did the 8g +/- wires, too since the ground was also showing strands being cut by the set-screw.

Going to try to get the rear speakers installed later today (with help from my wife after dropping it last time....).

And hope to have time this weekend to wire everything up and give it a real test run.

 

[FarFire70]

New BMB steering box skid installed into @Fluxor bumper. Was hesitant to drill into the new bumper but it went smooth through the steel corner & aluminum bumper. Used my new drill bit stops (very happy I have these!)

Before having the drill bit stops — I'm embarrassed to admit that I let the drill run long when I installed the cut-off switch for my underhood light. Resulted in a dimple in the hood....

Picture shows the light bend but in-person it's a clear 'zit' on the hood to be dealt with later.

 

[FarFire70]

Along with the above post of how the set screws tore into the wiring, you can see the separated threads left in the amp on multiple spots:

New amp ends wired up:

So much cleaner!

And I labeled these input adapters for the RCA cables

The ends of these wires appear so fragile. Would rather the RCA just went straight into the amp, but this is the design.

@NashvilleTJ Did some research and found a solution for one of these small connectors:

https://wranglertjforum.com/threads/a-rebuild-of-mirustyjeep.54728/page-40#post-1642514

Sharing to broaden exposure for Jeff's find! I bookmarked it immediately when he posted the above thread...

—-

Still need to install the rear speakers before I run the radio test. Life is in the way so maybe early next week for more work.

 

[FarFire70]

I'm also having an HVAC issue where I didn't realize the Blender Door Actuator was getting voltage and was making noise.

I pulled it and took it apart (no pics( but the gears weren't noticeably stripped enough to cause a gear slip.

But, I've done a lot of wiring work while the Jeep was parked. And part of that was to remove the AC Compressor cut-off switch that I had installed in the HVAC controller — Thinking that would save a few HP (it was the mid-00's — take that for what it was going around).

But, I don't know if I re-wired it wrong or if the new HVAC controller I installed caused the issue — The 'new' HVAC controller was apparently for a 97-02 and they changed the vac ports in 03+

So $200+ for a new HVAC controller...

I installed the new HVAC controller but haven't tested it yet.

——

I guess this is as much a post on 'another thing I'm working' and a bitch on the problem...

 

[NashvilleTJ]

Had an issue when I first tested wiring up the amp with the set-screws cutting through the wires. I probably went a little heavy-handed with the screw driver, but I didn't want the wires working themselves loose.

Either way, this is gross:

View attachment 700138

So I picked up a ferrule crimp end kit. My first time learning that these exist, but makes sense as a product/tool.

I went with this kit because it claims to be copper which I liked:

https://www.amazon.com/dp/B0CT5F94XB?tag=wranglerorg-20

This one gives a 6-sided crimp. Other ferrules offer a 4-sided/square crimp. New tool into my inventory (came with the kit):

View attachment 700141

And boom:

View attachment 700139

The plastic end slips over the wire insulator. I added heat shrink for added protection & strength.

I also did the 8g +/- wires, too since the ground was also showing strands being cut by the set-screw.

View attachment 700142

Going to try to get the rear speakers installed later today (with help from my wife after dropping it last time....).

And hope to have time this weekend to wire everything up and give it a real test run.

That's a very cool solution for those connectors. Nice work.

 

[FarFire70]

And I labeled these input adapters for the RCA cables

View attachment 700775

The ends of these wires appear so fragile. Would rather the RCA just went straight into the amp, but this is the design.

@NashvilleTJ Did some research and found a solution for one of these small connectors:

https://wranglertjforum.com/threads/a-rebuild-of-mirustyjeep.54728/page-40#post-1642514

Sharing to broaden exposure for Jeff's Mike's find! I bookmarked it immediately when he posted the above thread...

Thanks to @JMT for keeping me honest — The link to the replacement pin-connector into the amp from the RCA cables was from @Mike_H and not @Nashville. Thanks Mike for finding that solution! I know I'll need it some day when these fragile connectors break...

I did steal a lot of my amp under-dash mount design from @Nashville. I was doing a lot of research on the forum in deigning the radio system and must have gotten info from Mike & Jeff confused and didn't even look at the username when posting the link.

 

[FarFire70]

I hate logos, even ones no one will see but me:

More gap than I like but I ran out of Dremel cut wheels and went to a full sized grinder...

 

[FarFire70]

Similarly, GR put their logo here on my aluminum fenders:

I luckily found a set on vinyl logos to fit. x6 per side (facing forward on each 6) - x12 total. Only $4.99 shipped on Etsy.

Little Willy Jeeps to go on each side in black.

I'll put them on after I clean up the fenders first as they're very crusted right now as the fenders were the first aluminum on Homer but I didn't treat it early and left a lot of grease, sweat, etc on them.