brief Tinster "How To"

[Tinster]

brief Tinster "How To"

A few folks have asked me about the lexan box I had made
to protect my new Dan Masters Power Block main panel:

So here is a brief how to. My boxes can be used to protect
other componets as needed.

I carefully measured the Power Block and made a life size model out of
cardboard. I wanted a tight fit on the top/bottom
so the unit would not bounce around.

I took my model box to a plastic sheet supplier/fabricator.
I opted for Lexan since it is not as brittle as plexiglass.
I liked the high tech look of the 1/4" thickness, blue
crystal. The top edge is slightly longer- to cover the wires
as they exit the Power Block. The box is a monolithic piece of Lexan
with heat welded butt joints. I think I paid like $39
for the box complete.

The Power Block slides into my lexan box as shown in the photo.
The tops and bottom of the Power Block wires, etc touch the
box surfaces and keep everything from sliding around.

I installed small velcrow tabs to hold the Lexan box in place.
My box pops up with finger pull presure, the Power Block slides
out if new fuses, etc are needed. I keep a hex tool
taped to the lexan box for roadside repair of my Ratco cable
linkage, in case the cable pulls out.

My lexan box works just great, it looks pretty high tech and
it does not cost you your first born son.

I hope some folks find this How To of use.

regards,

dale

 

[NutmegCT]

Re: brief Tinster "How To"

Dale - you are a natural born "documenter"!

Couple questions ... does the Powerblock really need protection?

What's the big bundle of black tape at the side?

thanks.
Tom

 

[Tinster]

Re: brief Tinster "How To"

Couple questions ... does the Powerblock really need protection?

What's the big bundle of black tape at the side?
thanks.
Tom

Tom,

in my neck of the woods we have an active volcano, salty air
trade winds dust and normal roadway grit and grime. In my
case, I think the Lexan box is well justified. Remember, it
took me 5 months to install the complete car rewire system.

About 40 wires come out of the Power Block. These wires pass
thru my firewall in two existing holes. The black tape covers
the junction where the wires split off into either of the two
holes. There are wire ties under the tape.

I'm faily brain dead in things auto mechanical and even worse
in things electtical. That big glod of wires looked ugly to me
and I simply had not the experience to know how to properly
cover them. The black tape was my best effort.

I'm too far down the road now to disconnect all my bullet
connectors to try something else. The glob will remain.
It is functional. My car is no beauty or show piece but at least
it finally runs without constant breakdowns.

regards,

d

 

[weewillie]

Re: brief Tinster "How To"

Hey Dale did you know that you can brake form lexan as long as the bend radius is not too tight

 

[DNK]

Re: brief Tinster "How To"

Dale- Why is the bottom piece brown. Does it still have the paper on it?
I like it and will consider the same just might change the anchoring system.

 

[Tinster]

Re: brief Tinster "How To"

Yeah Don,

I left the shipping paper on the inside, bottom because
my Power Block platform has some sharp fastener bits
on the bottom side. I didn't want to scratch the Lexan.

Good eye ya got- picking up on that!!

d

 

[Brosky]

Re: brief Tinster "How To"

Thanks Dale. That confirmed your detailed phone explanation and I'll probably do something similar with my new Masters H/L relay wiring kit and the Spal wiring harness for the new electric fan.

 

[fogdot]

Re: brief Tinster "How To"

Yeah Don,

I left the shipping paper on the inside, bottom because
my Power Block platform has some sharp fastener bits
on the bottom side. I didn't want to scratch the Lexan.

Good eye ya got- picking up on that!!

d

Isn't it funny how we make something to protect something else, then we install abut four levels of protection for the protector of the thing protected.

 

[DNK]

Re: brief Tinster "How To"

I'm going to wrap the hole thing in bubble wrap to finish it off