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jgtech

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Reply with quote  #1 
I've been a bit busy over the last couple of months working long hours (After Hours) on developing a my own version of the Evolution style control panel. I first started with the idea that I would learn how to use Solid Works to minimise time spent cutting and modifying and Boy was I wrong. YouTube tutorials were helpful and confusing at the same time. Many Beers later I was able to work my way through it and finally came up with a drawing that could be sent to CNC Machine to have the panel cut out. The prototype was done in 1.6mm GAL - stronger than aluminium and the weight difference was minimal. I mounted it and it was overall a success.  I also made my own heater grill out of GAL and fan powered by the switch panel. I did have to make some changes as I was initially going to have it hinged with drop lock but the opening would be difficult with the limited room and the depth of the radio. 2017-08-10 19.48.07 (1).jpg  2017-08-10 19.48.42.jpg  2017-08-10 19.49.15 (1).jpg  2017-08-10 19.50.32.jpg  2017-08-12 11.01.44 (1).jpg  2017-08-30 11.19.32.jpg 

After the prototype I went back modifying the drawing, made my necessary changes and prepared for the somewhat overwhelming challenge of re-wiring the Conqueror and can honestly say I was quite shocked at what I found in the wiring department. Anyway, I pulled out all the existing gear labelled the existing wires and then lost my life for a couple of days!!

2017-08-20 21.06.19.jpg  2017-08-22 22.57.15.jpg  2017-08-23 22.15.21.jpg 
I was pretty happy with the final result and mainly that everything worked exactly the way I wanted. Isolated all power correctly with circuit breakers and now have full control of all individual accessories. The gear installed - Standard Double Din touch screen Android unit which has internet capabilities, Bluetooth etc - I had already installed 4 Speakers, Narva flush mount USB sockets, Redarc BMS 1230S2 30 Amp, Clarion AMP, Wireless fridge and freezer Temp monitor, Topargee Water Flow meter, 2 X 6 Gang Switch box, Heater Exchange. TV Bracket, Circuit Breakers form local Electrical shop, lots of Auto Elec parts. Sound is amazing now. I also insulated the speaker boxes with sound deadener. 2017-08-28 18.01.18.jpg  2017-08-29 00.40.07.jpg  2017-08-29 01.29.13.jpg  2017-08-29 01.44.07.jpg  2017-08-29 03.50.07.jpg 

I installed a 900W Projector Invertor below is the pics of how I mounted it. I wanted to keep the wiring as close to the batteries as possible. I put a 100 AMP Auto fuse from Jaycar inline for extra  protection. I added a double GPO from the invertor just left of the control box as can be seen in the last pic below
2017-08-27 11.37.52.jpg  2017-08-27 11.38.03.jpg  2017-08-30 12.05.36.jpg 

I have done other mods like storage lights. Each side controlled by its own switch. I will say this too was a very time consuming job!! but worth it 2017-08-18 12.00.03.jpg  2017-08-18 12.00.11.jpg  2017-08-18 12.00.21.jpg 

The only problem is unexpectedly now I have a customer that wants me to do the same to his Conqueror.

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Kbhallinan

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Reply with quote  #2 
Wow, that is bloody nice.

Haven't got a camper as yet but looking at putting something in play really soon.

Got a few things rolling around in my head. Some great ideas in your post.

Nice workmanship as well, you'd have to be happy with how it's turned out.

Cheer

Kieran
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Spada

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Posts: 138
Reply with quote  #3 
That's really nice work. [thumb] 10 outa 10 for the finish.

Like you, I too was shocked at the rats nest of bundled and twisted wires hidden behind the panel. I recon I nearly filled a bucket with the offcuts by the time I finished mine - http://www.conquerorforum.com/post/show_single_post?pid=1294086993&postcount=11&forum=305433 I'm not smart enough to learn how to use a proper design program, I had to scale mine as an XL file with every possible measurement, and then get some one to transfer it to a Cad file for the cutting. Luckily I've got a mate in the industry and was able to get a stainless panel made for nix [biggrin] 

Love seeing what mods people do............whats next on your list ?
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DTKK

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Reply with quote  #4 
Hi jgtech.

Unbelievable.

I'm not suprised someone has hit you up for the same. reckon you mite have to brace your self for the onslaught.

Love your work thanks for sharing.


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Dave and Tricia
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jgtech

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Reply with quote  #5 
Thanks for the compliments guys - glad you liked it.  I have other mods in progress and should be finished by the weekend. I'll share them with you when complete. 

Cheers Joe
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Kbhallinan

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Reply with quote  #6 
Hey Jgtech,

What was the light and switch unit u used in the storage compartments. They look a good additon!

Cheers

Kieran
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jgtech

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Posts: 38
Reply with quote  #7 
Hi Kieran,

I bought 2 packets of 10X LED in a one continuous string and just cut them up as I needed. The switch is just a standard switch I bought also from Jaycar . See attached pics. 2017-08-31 23.21.28.jpg  Jaycarled.JPG 

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filbee56

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Reply with quote  #8 
Huge effort Joe.  Envious of your skill, and motivation. 

Cheers, Filbee56

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2013 LC200 TTD Sahara - Ex-Demo 10/2014 UEV-490 Evolution with the lot.
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hassro

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Reply with quote  #9 
Nice work 👍🏼
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Prado Grande 120 - Conqueror Australia UEV 440
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jgtech

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Posts: 38
Reply with quote  #10 
I got the Conqueror finished and out of the Shed!! Tested everything and seems to be all ok. Put on switch at the entrance for a roof light - I attached some magnets to the back of the LED light and used some Narva connectors. This means I can change the light easily if it fails, remove if necessary also isolated at the control box. I'll get some pics up tomorrow. Bought a TV from Target yesterday and not too bad for the price.

2017-09-02 11.58.56.jpg   

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GainzWithGreens

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Reply with quote  #11 
Excellent work Joe! I've been toying with the idea to modify the switch panels for ages. They are absolute crap! The new ones are are not too bad, but I've got a 2012 Evo and these circuit breakers are not just awful to look at, they are also unnecessary (apart from the 240V ones).
I am about to chuck some solar panels on the roof and I want to get a regulator with its own monitor, so it's about time I design a new panel and get rid of the old stuff. Also need to fit USB ports and additional cig plugs.
Nice to see your mods and what can be done. Agree, trailer wiring is shocking, I have to give most of it to the sparky and afraid that it will turn into a Pandora's box...
Planing to use 2mm stainless steel 316 and get it gut with a water jet. Need to find a proper marine switch panel and get rid of most of circuit breakers. Which of the 240V ones did you end up keeping/swapping?

Cheers,
Sascha
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jgtech

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Reply with quote  #12 
Hi Sascha,

The switch panel I used are circuit breakers with switches. They have Butyl rubber gaskets and IP66 rated so suited to exposed environments. 2mm might be a bit excessive but definitely strong. The 1.6 GAL I used is more than strong enough.

I used the 240V circuit breaker for the AC power, Ext Pressure Fan and 12V Battery Isolation.

Cheers Joe.



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GainzWithGreens

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Reply with quote  #13 

Hi Joe,
Could you post a link to the 240V circuit breakers you used? I've also been looking at marine switch boards and would like something with custom labelling, switch illumination (which can be turned off) and of course IP66.
The one I like is this sort of style:
http://www.ebay.com.au/itm/10-Gang-Boat-Marine-LED-Rocker-Switch-Panel-Circuit-Breaker-Voltmeter-12V-24V-AU/172660966186

Unfortunately, being ebay, I am unsure of the quality and durability.

Cheers,

Sascha

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Spada

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Reply with quote  #14 
Dont want to hijack the thread, as Joe has done a cracker of a job, but maybe this info might be of use.

When I did my panel, I retained all of the original breakers for both the 240v and the 12v. I bought one of these- https://www.bunnings.com.au/deta-8-module-surface-mounted-switchboard_p4330992 from Bunnings, carefully removed the cover and threw the case away. I had a small mounting strip made to take the cover and use a small bit of velcro on the bottom edge to keep it closed. This does a reasonable job of hiding the breakers, but leaves them easily accessible. I had some nice laser etched lables made for the breakers.

For the switches, I used illuminated carling switches from here- http://www.dukes4x4andcamping.com/laser and wired the illumination on it's own circuit so I can turn it off at bedtime.

Cheers
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filbee56

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Reply with quote  #15 
That pre-wired 10 gang panel Sasha looks great. Thankfully, the control panel on our 2014 built 490 Evo is pretty good. 

Cheers, Filbee56

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2013 LC200 TTD Sahara - Ex-Demo 10/2014 UEV-490 Evolution with the lot.
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