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Building a Relay Distribution Board for ATVs: A Step-by-Step Guide

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This is a WIP

I’m embarking on a project to construct a comprehensive relay distribution board, designed to incorporate all necessary controls, and mounted on a compact board or cart for demonstration purposes. The aim is to create a miniature, functional model using aluminum and/or wood, providing a tangible and visual aid for learning and display. The panel will be crafted from durable ABS plastic, adhered with a suitable glue. This project will start with the basic circuits commonly found in most ATVs and gradually incorporate more complex elements typically seen in road vehicles, such as horns, turn signals, and emergency signal circuits. There’s even potential to expand into trailer circuits in the future. Join me as we delve into this hands-on, practical exploration of ATV electrical systems.

Negative switching- safer? Not hot

  1. 12 volt battery
  2. ABS Plastic Sheet
  3. Glue (suitable for plastic)
  4. Relay(s)
  5. Fuse(s)
  6. Wiring (various colors for different purposes)
  7. 100-amp Breaker
  8. Starter/Ignition System
  9. Lighting Controls: (driving: Hi, low beam), markers, turn signals.
  10. Emergency Lights System: When done properly, does not require ignition key to be on, which I believe means it should be on its own circuit.

Need a more detailed materials list, wiring diagram, CAD project file (will also make a How To video doing this using Blender). Files and everything will be stored and shared on Nextcloud and shared with Patreon members, Hive supporters.

Comprehensive Documentation.

To ensure clarity and ease of following along, every step of this project will be meticulously documented. This includes:

  1. Spreadsheet: A project management spreadsheet will be used to keep track of all components, their specifications, and their roles within the system. This will serve as a quick reference guide throughout the project.
  2. Wiring Diagram: A detailed wiring diagram will be created to visually represent the connections and layout of the electrical system. This will be an invaluable tool for both assembly and troubleshooting.
  3. Component Labeling: All components and sections of the wiring harness will be clearly labeled. This will help in identifying each part and understanding its function within the system.
  4. CAD and Technical Drawings: Any CAD models or technical drawings created during the design process will be included in the documentation. These will provide a detailed visual guide to the physical structure and layout of the relay distribution board.

All documentation will be stored on Nextcloud, ensuring it’s easily accessible and securely stored. This thorough documentation will not only guide us through this project but also serve as a valuable resource for any future modifications or troubleshooting.

Wire Color convention:

  • Red= positive power
  • Black= negative
  • White= switch
  • Blue= device