Small Electrical box for chopper $10

[CoastsideXS650]

Here are some pictures of the box I used to hold all of my wiring and switches.
The bike is kick only, PMA, small battery, only head/tail/brake lights. This is about as minimal wiring as you can get.

I mounted the regulator on the lid of the box. It is an electrician's 4 11/16" box and a gasketed cover. You can find them for $10 at Garvin.

http://www.GarvinIndustries.com/electrical-junction-boxes/4-11-16-junction-boxes/2-1-8-deep-with-conduit-knockouts/72171-blnk
And in Stainless Steel
http://www.GarvinIndustries.com/electrical-junction-boxes/4-11-16-junction-boxes/2-1-8-deep-with-conduit-knockouts/72171-blnkss
Cover
http://www.GarvinIndustries.com/electrical-box-covers/4-11-16-square-box-covers/flat-covers/72c1-vt

Everything is designed to come apart and out of the box easily and without damage to the harness.

Everything fits in there with just the right amount of breathing room. All nice and insulated and working perfectly. Its these little things that I love most about building my own motorcycle.

The switch is for the lights. The key switch is my kill switch.

 

[h3llb3nt1]

The elec. Junction box is a great idea. Nice job man

 

[glennpm]

Excellent idea and great pictures documenting your project! I think I'm going to do the same.

Doesn't seen that Lowes or Home depot carry the blank boxes although I did find a PVC one with a sealed cover:

http://www.lowes.com/ProductDisplay?partNumber=10008-223-E989NNJL&langId=-1&storeId=10151&productId=3127463&catalogId=10051&cmRelshp=req&rel=nofollow&cId=PDIO1

 

[4stroke]

where did u find the blade fuse holder

 

[grepper]

Nice, you might want to keep an eye on it as the vibrations and bumps might shake loose or crack it. Maybe mount it with some grommets and/or so big fender washers to distribute the weight around the bolts.
(I have had more than one thing fall off my bike before)
As for the blade fuse box, many auto parts stores have them, I got mine off of eBay for like $5.

 

[501Spanky]

Great idea! By the way, those are awesome fender mounts!

 

[CoastsideXS650]

Excellent idea and great pictures documenting your project! I think I'm going to do the same.

Doesn't seen that Lowes or Home depot carry the blank boxes although I did find a PVC one with a sealed cover:

http://www.lowes.com/ProductDisplay?partNumber=10008-223-E989NNJL&langId=-1&storeId=10151&productId=3127463&catalogId=10051&cmRelshp=req&rel=nofollow&cId=PDIO1

Im an electrician and I could not find one of these in any of the wholesale stores in my area. Even the big electrical places didn't stock them. I found it after looking thru some electrical catalogs.

 

[CoastsideXS650]

where did u find the blade fuse holder

Ebay dude. just type mini blade fuse block or holder or some other combination of those words.

 

[CoastsideXS650]

Nice, you might want to keep an eye on it as the vibrations and bumps might shake loose or crack it. Maybe mount it with some grommets and/or so big fender washers to distribute the weight around the bolts.
(I have had more than one thing fall off my bike before)
As for the blade fuse box, many auto parts stores have them, I got mine off of eBay for like $5.

10 steps ahead of you. Got some fender washers and lockers on that bad boy for that very reason. I was also thinking about putting a small strip of rubber between the frame and the box to help soften vibrations too.

 

[DaveO]

Good post. It got me curious. Anyway, for anyone in the UK Maplins sell similar stuff.

Black plastic, various sizes £4.00 - £10
http://www.maplin.co.uk/mb-plastic-boxes-1676
Grey plastic, various sizes £3.00 - £7
http://www.maplin.co.uk/project-boxes-265960
cast Aluminium £4.00 - £16
http://www.maplin.co.uk/eddystone-die-cast-aluminium-shallow-lid-thin-wall-43713

All have screw down lids which look pretty water resistant.

Hope this helps someone.

Dave

 

[pahako]

Here is a source for project boxes in the US. There are more if you look around.
http://www.parts-express.com/cat/project-boxes/1450

 

[WacoBrian]

Here is a source for project boxes in the US. There are more if you look around.
http://www.parts-express.com/cat/project-boxes/1450

nice find, thanks for sharing.

 

[Metalredneck]

Good stuff. My last box was UUUUUGlee.

 

[4stroke]

i cannot find one of those mini blade fuse blocks any where!!

 

[grepper]

i cannot find one of those mini blade fuse blocks any where!!

On Ebay
http://www.ebay.com/itm/ATC-ATO-4-way-Standard-Side-Terminal-Fuse-Block-No-Cover-/350733293284?pt=Boat_Parts_Accessories_Gear&hash=item51a95556e4&vxp=mtr
http://www.ebay.com/itm/ATC-ATO-4-WAY-FUSE-BLOCK-WITH-CLEAR-COVER-SIDE-BLADE-AUTO-CAR-TRUCK-MOTORCYCLE-/230941641329?pt=Motors_Car_Truck_Parts_Accessories&hash=item35c531ca71&vxp=mtr

At your local auto parts store
http://www.oreillyauto.com/site/c/detail/LIT3/350418BP/N1177.oap?ck=Search_fuse+blocks+%26+holders_-1_3356&keyword=fuse+blocks+%26+holders

 

[501Spanky]

i cannot find one of those mini blade fuse blocks any where!!

I use this one: http://www.princessauto.com/pal/product/8138224/ Princess Auto in Canada. 6 circuit with a ganged hot.

 

[4stroke]

great thanks guys!!! i must have been mis wording it when i was searching!!

 

[A5HLEY]

Which wires go to what on the universal key switch? I got the same 3 position switch from TC bros and dont know how to wire it up. Im running kick only. Switch has B, IG and L??

 

[grepper]

Which wires go to what on the universal key switch? I got the same 3 position switch from TC bros and dont know how to wire it up. Im running kick only. Switch has B, IG and L??

I would suggest you just get a multimeter and test what each position does. I believe all you're really looking for is On/Off functionality.

 

[CoastsideXS650]

Yeah, You should get a multimeter and test for continuity across each key position.

But if you don't have one and cannot wait. I believe B is your hot from the battery (after the main fuse of course), Turn the key one position and it hots up IG, turn the key to the number 2 position and it hots up both IG and L.

But like Grepper said, get a multimeter. This is a tool you should have before you ever touch the wiring on your bike. You can diagnose just about every electrical issue possible with a $20 meter.