Building Homer (2005 TJ Build Thread)

[Mike_H]

When I installed a new headlight harness, I ran new wires for power and used the existing headlight wiring to trigger new relays. It’s been that way for as long as I’ve had my Jeep ( going on 7 years). Upgrading the headlight circuit was the very first mod I did. Don’t make the project harder than it needs to be.

 

[FarFire70]

When I installed a new headlight harness, I ran new wires for power and used the existing headlight wiring to trigger new relays. It’s been that way for as long as I’ve had my Jeep ( going on 7 years). Upgrading the headlight circuit was the very first mod I did. Don’t make the project harder than it needs to be.

Yup - I over-thought the solution. I'm going to cap off the driver side wiring within a foot or two of the firewall, using heat shrink on the end of the wires, and bury them within the loom.

I'll use the passenger headlight wires to trigger the planned relays for direct battery-to-headlight wiring. Thinking to build up a bracket on the side of the PDC for the relays/fuses. New PDC (forthcoming) doesn't look to have 12g to any of the relays to use...

—-

So I didn't need to dive within the PDC... but I'll clean up the electrical tape with heatshrink while I'm there.

 

[FarFire70]

Working on the headlight loom.

Sealed up the driver side.

Tore apart these self-sealing connectors to ensure I could close them off with heat shrink.

All the tools needed:

I ended up using the red handle crimpers to double check the auto crimpers because my first try fell off...

I think that was user error, but it was a good double check by a more basic tool to confirm a solid crimp.

 

[FarFire70]

I cut this cable based on a TSB from Jeep. I still wasn't sure at the time whether I may need to connect it again, so looks like I planned ahead..

It's funny to find these things realizing I didn't just cut off the wire but also built in a backup plan. Things you forgot you did.

The TSB was because the Jeep would not clear emissions testing.

All its emission monitors properly and could leave more than two even when the Jeep was ready for emission testing.

In this state I was in you couldn't have more than two the emission monitors unset...

Now all set when the Jeep is driven long enough to set the emissions conditions...

At this point I'm going to seal them up too.

 

[FarFire70]

Also, I did a really poor job on this hatred at the time...

Young, dumb, cheap (poor) at the time...

 

[FarFire70]

CORRECTION: this wire (GN/WT) is for the fog lights. I cut it so that the fog lights could be on with high beams.

This wiring fix I did was for the TSB...

Memory is a funny thing...

If anybody needs this TSB change let me know and I'll get you the proper information...

 

[FarFire70]

So... Ready to drive tomorrow?

No

 

[FarFire70]

I joke about driving the Jeep tomorrow because there are so many projects to hit before then..

But, these hanging fog light wires are now better sealed.

Still need to build a plan and mounting bracket for the headlight wiring harness.

Thinking it'll look something around here:

Need to confirm hood clearance...

 

[FarFire70]

FWIW

I'm under impressed with these:

For a single ended connector on these terminations, I still used these to confirm a solid connection...

Otherwise the connector was loose and or or just slipped off...

So I'm likely still in search of the right tool.

 

[FarFire70]

Gray line is the exterior hood line, Black line is where the hood lip stops internal to the engine bay.

I don't see how I can make this work with the wiring and not obnoxiously encroach on the battery.

I think this area is pretty much useless (because of the AC lines) for anything else. So, I'm thinking this is likely where the headlight relays will live.

This is my first attempt at prototyping these relays so maybe options present themselves but this looks most likely...

 

[FarFire70]

Went through the new (used eBay) PDC to go in for new circuits and cleaned it up and removed fuses/relays. Realized it didn't come with the mounting bracket so picked one up of eBay to arrive later this week (TJ parts are just stupid expensive as they age...)

I plan to install the second PDC and use that for the fuses for the headlight relays.

I'll use external relays because there isn't enough in the PDC that use 12g wiring. I want that bigger wire direct to the headlights.

 

[FarFire70]

Can't work on the body work right now.

I'm waiting on a new PDC bracket to install a new /used PDC that will be used for the fuses to the new headlights.

So I moved on to the next project and decided to remove the radio.

I found out a likely cause of why my AM/FM radio has sucked...

Outer connector pulled off and left the internal pin that you can see sitting on the HVAC controls...

 

[FarFire70]

Not to give a guide to Future criminals... Pat Jeep did a nice job installing a anti-theft device for this radio...

It was a pain in the ass to remove so I guess Jeeps succeeded and its mission...

I couldn't figure out why the radio wouldn't move and figured it was wiring binding... This anti-theft device was the cause.

 

[FarFire70]

Stock dash speakers removed.

I have new pods and speakers to go in with new wiring so the OEM will probably just hang in the dash.

 

[FarFire70]

I have two of these HF Braun LED lights on a stick and my overall review is about a 5 out of 10.

These are some of the early versions so they may have changed them because the newer ones shown in the ads look different.

But they run out of their battery too quick. Just, not as great as I need.

 

[FarFire70]

Console out. A lot more work than I anticipated, but it's out.

New bass will go in before the console is reinstalled...

 

[Rickyd]

Console out. A lot more work than I anticipated, but it's out.

View attachment 555221View attachment 555222

New bass will go in before the console is reinstalled...

Hiding a kilo of Scott's in your center console?

 

[FarFire70]

Sub removed along with the oem amplifier. I had replaced the sub before.

New sub going in and all new wiring from audio amplifier going in so everybody came out.

I had hoped to fill the amplifier void with polyfill. But, I think I gave away the box I had so I need to pick that up at the store.

FWIW - that brown and black wire on the OEM wiring harness is how you wire in a new subwoofer to replace any original. The Phoenix subwoofer that I did replace the OEM that was blown out was pretty good for the money.

 

[FarFire70]

Hiding a kilo of Scott's in your center console?

It would probably do as well in my Jeep as it does in the grass — I tell my wife 'the yard may be full of weeds but at least they're green...'

I keep trying... But I don't have the attention to detail. So, the yard gets fertilized throughout the year but it still looks like what it does when I started...

 

[FarFire70]

I ran out of the magnetic bins that I use from HF ... Joe, every set of screws or bolts that came off got wrapped in labeled painters tape...