[w9kh_kevin]

Has anybody built their own solenoid box, or used a different box from what they got with their winch?
Here's what my fiddlin' @$$ did.... I went to mount the solenoid from my Vortex winch under the hood. All was going well until I went to attach the cables. Part of the cable was too close to the body, so when I tightened down on the connector, I wound up breaking the stud on the solenoid.
To shorten a boring (embarrassing) story, I picked up 4 solenoids from Grainger and plan on wiring it up myself. I just need to come up with a waterproof enclosure for them (dust proof solenoids, not water proof) and a mounting location.
Has anybody done this kind of building from scratch? What did you use for an enclosure? I was thinking about mounting it on the extra battery tray on the driver side. I know the shortest wire distance is best, but would that be an ok location?

[w9kh_kevin]

for ideas

[Unlimited04]

buy a Pelican case - Welcome to www.pelican.com Pelican™ Products

drill some holes in the side for wires and use silicon to seal em. I have used these cases in very demanding applications and they are nearly indestructable. They also carry a lifetime warranty, we able to destroy rolling wheels and latches, but they were covered no questions asked.

[Faramir66103]

This is what I was going to suggest. Their lifetime warranty does have some limitations though. A buddy of mine recently got one and on the inside it had a sheet spelling out the warranty. It mentioned it was a lifetime warranty if the gasket was lubricated or replaced annually and other such things, then it had it's last sentence in red ink. It said "This warranty does not cover bear attack, shark bite or children under five." I kid you not! My friend has several kids just over that age and we got a good laugh that kids under five were considered the destructive equal of sharks and bears.

FWIW,
Adam

[w9kh_kevin]

If I could weld, that would solve all my problems!

[w9kh_kevin]

I can't believe nobody else has had to do something similar.... Did I f it up that bad, or am I just trying too hard to over-engineer something?

[bonza]

OK, I understand what you are trying to do

this is what I did for having an underhood solenoid box for my Warn winch. instead of fabbing a new one, I mounted the existing unit to the base for the ABS servo, the thing that looks like a second battery holder.

like you I snapped a stud where a cable connected to a solenoid coil. To overcome this I fabbed a bracket that mounted the solenoid box high enough off the base so that the cables could bend with out straining the coil studs. you have to make sure that you use very flexible cable as well. the original cable I used was very stiff.
end result. the original Warn solenoid box is now mounted very firmly to the ABS base and there is enough gap between the two for the cables to thread and connect to the solenoid coil studs

dont know if this is helpful for your situation

[w9kh_kevin]

Are you talking about the location under the master cylinder? I was wondering about using that spot, but didn't know if that would make the cable runs too long.
I am using 2 gauge welding cable. It's very flexible and good for high temp.

[bonza]

Originally Posted by w9kh_kevin

Are you talking about the location under the master cylinder? I was wondering about using that spot, but didn't know if that would make the cable runs too long.
I am using 2 gauge welding cable. It's very flexible and good for high temp.

thats correct. under the brake master cylinder.

I used welding cable as well for the same reason. very flexible.

installed it over three years ago and has been trouble free.

[w9kh_kevin]

Great, thanks! Now all I have to do is come up with some kind of box. The original chinese solenoid was plastic. The ones I picked up are metal with larger lugs. I went from 1 to 4 solenoids, so it won't fit in the original box. I have to come up with a box that will work to fit the solenoids and fit in the space available.

[w9kh_kevin]

anybody? anybody? Bueller?

[cwildmann]

I am in the process of building my own solenoid pack and box that is completely different from the manuf. I went with these solenoids as I have a permanent magnet motor:

WINCH MOTOR REVERSING SOLENOID CONTACTOR RELAY 6 Term: LRW6001 DB Electrical Starter-Alternator

And I was thinking of fabbing a cover out of plexiglass - but your project got me thinking of using a plastic electrical box to seal it up:

McMaster-Carr

I recommend checking out the Corrosion Proof Polycarbonate housings.

You should definetely be able to find the perfect size for whatever project your doing. Also Radioshack sells cheap project enclosures but I don't think they make one big enough for 4 solenoids.

Hope this helps.

[w9kh_kevin]

These are the solenoids I got
http://www.grainger.com/Grainger/wwg/productIndex.shtml?from=Search&newSrch=yes&operato r=keywordSearch&search_type=keyword&action=Go!&Que ryString=6c028&submit.x=0&submit.y=0
I thought about the radio shack boxes, I wasn't sure if they would stand up to the heat under the hood though.
I think the location has settled to the platform just below the master cylinder. That is the only spot with enough room to put something like that.

[w9kh_kevin]

Found an enclosure for my solenoids. I gutted a non-working small astron power supply. I have to patch some holes and wire it up yet. Looks like it will wind up sitting in the space in front of the air box. It won't quite get down below the master cylinder. I will have to do some custom construction to make that happen. Not having a welder to make it up right really limits options.

[w9kh_kevin]

So far....





And this will likely be the location. I have to make a bracket to hold it there yet....