Building Homer (2005 TJ Build Thread)
- Thread starter FarFire70
- Start date
On the HVAC relay packs wiring, I started to remove the old old crappy electrical tape and replace it with good....
And then I found this...
Clearly the heat shrank on this splice didn't take... I need to redo all the splices because I just don't trust any of these soldered joints and my heat shrink at the time...
And then I found this...
Clearly the heat shrank on this splice didn't take... I need to redo all the splices because I just don't trust any of these soldered joints and my heat shrink at the time...
In fairness to the crappy electoral tape I'd use at the time, the OEM tape also is showing age...
Projects become projects...
Projects become projects...
Removed all the ancillaries I had added over the years on to these cigar lighter ignition-triggered wires.
New wires with the auxiliary PDC will resolve all of these connections.
I will clean this up with chrome connectors for straight wiring to these connectors. The connectors will go to the new new switch panel.
New wires with the auxiliary PDC will resolve all of these connections.
I will clean this up with chrome connectors for straight wiring to these connectors. The connectors will go to the new new switch panel.
I'm looking forward to actually wiring the Jeep appropriately for the long-term rather than all this hodgepodge I've done since I owned it.
I will "blame the previous owner" because that was me.
Homer was stock went I bought it barely used.
I will "blame the previous owner" because that was me.
Homer was stock went I bought it barely used.
I'm looking forward to actually wiring the Jeep appropriately for the long-term rather than all this hodgepodge I've done since I owned it.
I will "blame the previous owner" because that was me.
Homer was stock went I bought it barely used.
Nothing at all wrong with learning from previous mistakes - that’s why it’s called learning. Experience is the best teacher because the lessons tend to take. I also fix a lot of stuff on my rig that was screwed up by the previous owner…
Nice work.
Mounting bracket for Aux PDC arrived from eBay.
Tried the wire wheel in the drill but wasn't doing enough so switched to the wire wheel grinder.
Borrowed the idea of a box paint booth from @Wildman's build thread since the Jeep is in the garage and unmovable.
Side one painted black.
Also took a few minutes to tidy up the garage. That's always a great feeling when you can find things and walk around without having the strategically place every step...
Tried the wire wheel in the drill but wasn't doing enough so switched to the wire wheel grinder.
Borrowed the idea of a box paint booth from @Wildman's build thread since the Jeep is in the garage and unmovable.
Side one painted black.
Also took a few minutes to tidy up the garage. That's always a great feeling when you can find things and walk around without having the strategically place every step...
Always glad to share ideas. Can't tell you where I picked up the idea from.
I really need to do a deep cleaning of my garage.
Ordered a pair of Klein terminal/connector crimping pliers.
Klein Tools J1005 Crimping Tool
And Klein larger gauge cutting pliers (with integrated stripper).
Klein Tools J63225N Journeyman High-Leverage Wire Cable Cutter and Stripper
These will help with the 8g for the amp. I swear I had a set but can't find them. Klein will be better quality anyway....
Klein Tools J1005 Crimping Tool
And Klein larger gauge cutting pliers (with integrated stripper).
Klein Tools J63225N Journeyman High-Leverage Wire Cable Cutter and Stripper
These will help with the 8g for the amp. I swear I had a set but can't find them. Klein will be better quality anyway....
Brown truck Santa decided I was on the naughty list and delivered my package to my neighbor....
But I was tracking it and sent neighbor a heads up text that I wasn't stealing packages but getting mine. LOL I actually just delivered a package to them this morning that was delivered to my house yesterday by USPS...
Getting excited for this wiring project!
But I was tracking it and sent neighbor a heads up text that I wasn't stealing packages but getting mine. LOL I actually just delivered a package to them this morning that was delivered to my house yesterday by USPS...
Getting excited for this wiring project!
Planning to drill into the firewall. Stealing from @Chris post in
https://wranglertjforum.com/threads...through-firewall-with-pics.52002/#post-945503
Thinking to go with one but maybe two to fit all the wires to the switches from the aux PDC.
Measured out my grommets from this kit.
Grommet Kit
They measure 0.95" for the ones I'd like for the number of cables to pass through.
https://wranglertjforum.com/threads...through-firewall-with-pics.52002/#post-945503
Thinking to go with one but maybe two to fit all the wires to the switches from the aux PDC.
Measured out my grommets from this kit.
Grommet Kit
They measure 0.95" for the ones I'd like for the number of cables to pass through.
Tried an initial removal of the HVAC blower motor and couldn't figure it out...
Read the service manual and there is a "release tab"
F the service manual....
The service manual can't point to the 'locking tab' in the figure that does 'point to the blower motor' that you're removing....
Oh — and if if you missed it — that plastic box is the 'HVAC housing'....
Read the service manual and there is a "release tab"
F the service manual....
The service manual can't point to the 'locking tab' in the figure that does 'point to the blower motor' that you're removing....
Oh — and if if you missed it — that plastic box is the 'HVAC housing'....
All right, cooler head this morning got out the blower motor...
Going to price out a new one while this one is out since this one is at 150k miles.
Going to price out a new one while this one is out since this one is at 150k miles.
Firewall all holed up 
Pair of these going on when the paint dries (15.88x24.61mm):
Threw on a coat of the Automotive Touchup paint after hitting each hole with the new deburring tool.
Deburring Tool with 10 Extra High Speed Steel Swivel Blades
Deburring tool did a great job! Going to grab the additional bits for blind holes as it left some shavings to address in the engine bay when I first used it from within the cab. Plan to use it for the slider holes to clean them up, and some are blind...
Automotive Touchup paint looks to be a close match. Tough to tell though when hitting a hard edge like these holes.
Pair of these going on when the paint dries (15.88x24.61mm):
Threw on a coat of the Automotive Touchup paint after hitting each hole with the new deburring tool.
Deburring Tool with 10 Extra High Speed Steel Swivel Blades
Deburring tool did a great job! Going to grab the additional bits for blind holes as it left some shavings to address in the engine bay when I first used it from within the cab. Plan to use it for the slider holes to clean them up, and some are blind...
Automotive Touchup paint looks to be a close match. Tough to tell though when hitting a hard edge like these holes.
Stepped bit for the holes from within the cab after an initial 1/8" pilot. Needed that motor out to get drill lined up for both holes.
Planning for one hole for the 8g to the radio amp. Likely use that hole also for power to the seat heaters.
Second hole for all the wires to the switches.
With the Aux PDC next to the stock one, these access points with significantly cut down on the length of runs into the interior.
Planning for one hole for the 8g to the radio amp. Likely use that hole also for power to the seat heaters.
Second hole for all the wires to the switches.
With the Aux PDC next to the stock one, these access points with significantly cut down on the length of runs into the interior.
Tested out the print to find the right size - smallest 8 font should work.
Now that looks good. Something so soothing about printing labels...
Still plenty of growing room in this Aux PDC.
Now that looks good. Something so soothing about printing labels...
Still plenty of growing room in this Aux PDC.
It's interesting in the difference between the early PDC & the later PDC. The later year PDC's are filled a lot more. My 97 PDC isn't as detailed either.
I just happened to stumble across an 05 PDC when I was started looking on eBay to actually buy one. Makes it easier to just have 1 FSM handy to look up the circuits.
Agreed - very interesting how much changed in just 8-10 years. I always find it interesting seeing the larger fuses in the early TJ PDCs - just a jarring sight when you're used to the newer/smaller high-amp fuses.
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