It's an option under consideration but not very likely for me. The stock doesn't have enough relays for everything I want so I would have to design something else anyway. Also the spot on the fender next to the PDC is where the cruise control sits on my 91.
If you're willing to do about an hour of playing with dental picks, you can get up to one dozen mini-ISO SPDT relays into the sucker (3 4-socket modules), as well as a full standard complement of maxi fuses and a few mini fuses. Each row of relay sockets is actually removable and swappable, you just have to get enough PDCs to disassemble for the parts you need.
EDIT: and from pics I found online (I don't have mine in front of me right now) you can fit another two next to the mini fuse section, for a total of 14.
this is what i have done for my relays. The plugs are connectable so i can add on. Relays are waterproof and a dab of lanocote on the spades and some silicone in the back of the plug i would say that it would be pretty dang waterproof.
I am currently working on this - I'm putting all my relays in a rebuilt stock PDC (I have another one mounted in the trunk area for my OBA relays and such.) Pulled the PDC and bracket from the junkyard for $20, disassembled it fully while sitting by the fireplace at thanksgiving and rewired it to do exactly what I wanted. The bracket is riveted together in the middle so I am going to grind out the rivets and use the top half plus a new bottom half bent to make it fit on the driver side inner fender, where the ABS pump would go.
I'm looking at this more closely. I had not previously noticed that the inserts are modular, so that is a big plus. It also looks like the inserts might be standardized, since my dad's Taurus seems to have the same thing. The local junkyard has a bunch of these in their WJ aisle so I could probably get some there too. Looks like 16 of the small relays and 14 maxi-fuses will fit pretty easily, just have to do some shuffling.
I assume the small relays work like the traditional Bosch five-pin relays? Do you know what amperage they are rated to carry? http://www.rallylights.com/detail.aspx?ID=980 says they are only 10/20A which limits their utility
Not sure, but I seem to recall seeing at least one fed by a 30 amp fuse when I tore one down. Might be wrong on that, I'd have to check again to verify. The mini-iso fuses are almost all SPDT which is a plus in my book, they should have a wiring diagram on the side or top of the casing.
Not sure how easy it'll be to increase the number of maxi-fuses past whatever came in the PDC - the section of the block that feeds the maxi-fuses is a large pressed copper buss bar, with the feed terminals of each maxi-fuse crimped on. I would personally not want to try adding more feed terminals. The box I have sitting here has 8 maxi-fuse slots populated, and I think my other one has more (option dependent) so your mileage may vary on that.
Probably one of the large relays... 20 amp can handle ~240 watts at 12v so that is pretty powerful regardless, and more than capable of handling most lights. I may leave a couple of the large Bosch relays in there for the fans and whatnot.
Not sure how easy it'll be to increase the number of maxi-fuses past whatever came in the PDC [...] The box I have sitting here has 8 maxi-fuse slots populated, and I think my other one has more (option dependent) so your mileage may vary on that.
I looked at a 95 today and it had 2x7 slots. Here is a pic I found online which shows it. 14 maxi-fuses is plenty
If it's possible to eliminate the mini fuse section and install three of the micro relay sections, I can get get 12 of the micro relays, 2 of the large relays, and 14 of the maxi fuses. Is that doable?
I also think I have figured out a way to make space on the fender wall next to the real PDC, but I need to get a 95-96 A/C suction hose to replace the stocker on my 91 (they go over there to avoid the old-style oil filter location)
That's what I'm saying - it may not be possible to fill up all 14 maxi fuse slots. The two center terminal rows of that section are fed by a copper plate with things crimped to it - you'll see what I mean if you pop the bottom housing off.
Also, I like the look of that minifuse section, the one I have has 6 minifuse sockets (5 populated) and 2 mini-iso relay sockets in that spot.
EDIT: just popped my spare PDC apart, seems that a 40 amp fuse in the second slot up from the bottom on the left column (relays at the top) feeds terminal 30 on the starter relay, though there is a second wire from that maxifuse so it may not be handling the full current. A 30 amp fuse next to it feeds terminal 30 of the A/C clutch relay so I guess the A/C clutch relay (part number 4671168C on all the mini-iso relays in this PDC) can also handle at least 30 amps.
What about a newer TJ PDC? I've seen a pic around (getahelmet maybe?) that looked similar to the XJ PDC, but used the odd breakers instead of fuses, and I believe it had 2 mini relay blocks. Just a thought, have to verify it.
Are the PDCs specific to Jeep, or parcticular platforms, or do other DCP vehicles use them? Looking again, I don't think it's exactly like ours, but I wonder if the blocks are interchangeable.
I haven't done any water proofing, but I stay from water and mud as much as possible. It's been splashed pretty good and the inside has stayed cleaned.
A extra stock PDC? That's brillant. I need to get into my stock one anyway to 'fix' the stock foglight relay. (mine did not have factory fogs, so I used parts from the boneyard to add them) I was scratching my head about how & where to add 3 or 4 relays and a few extra fuses.
I'm going to bring this thread back to life because it covers all the different fuse/relay blocks I found while searching except this one (which as far as I can tell is a fairly new product):
Available in a couple different flavors, and they're sealed. Del City sells all the wire seals/plugs/etc as well (must be purchased separately), or Dirtbound Offroad sells a complete kit including relays. The only downside is that the mini-relays I have found only handle up to 20A(NC)/35A(NO). Which in most cases will not be a problem, but the way my e-fan over-ride is setup I need more than 20A on the NC circuit.
Still, thought it was a pretty cool product that I hadn't seen mentioned before. I'm thinking I'm going to pick up one of the Hella 4 gang relay block and one of these to get all the circuits/relays I need and finally clean up all my added on wiring.
There is a guy on ih8mud who will build you one all prewired and such. I bought one from him and the switch setup from prime 4x4. Very happy with the setup. He said that box is only rated at like 50amps or something like that so you don't want to hook up too much stuff to it.
There is a guy on ih8mud who will build you one all prewired and such. I bought one from him and the switch setup from prime 4x4. Very happy with the setup. He said that box is only rated at like 50amps or something like that so you don't want to hook up too much stuff to it.
The one with 5 relay slots/10 fuse slots is rated at 30 amps per branch, and the input is rated at 80 amps max. So no, it's not a huge panel but considering it only accepts the mini relays that are only rated for 20-35 amps anyway, I don't think it's a huge deal. It would easily handle two sets of lights on the front, and a set of backup lights, plus a few smaller things. Also have to consider whether or not you'll be using everything at once (you probably won't).
It's not for everyone, but the cost is reasonable and it's a slick package if it fits your needs.
