P1000 Cooper Bussman Extremely Detailed Build Tutorial

[Jediwrathchild]

@SikorskyGramps haha I hear ya on being the mule. Somehow I always end up with all the gear and pulling a trailer!

 

[AKRider]

@SikorskyGramps haha I hear ya on being the mule. Somehow I always end up with all the gear and pulling a trailer!

Same here, and I've pulled a lot of gear up and down some pretty interesting areas. Low with the RPMs up ;-)

 

[Jediwrathchild]

Same here, and I've pulled a lot of gear up and down some pretty interesting areas. Low with the RPMs up ;-)

And it impresses me every time, chugs right along without skipping a beat!

 

[AKRider]

And it impresses me every time, chugs right along without skipping a beat!

Yep! I love this machine!

 

[JTW]

Welcome from Kentucky Gramps... can't wait to see the pics! You should know that it's a site rule that you HAVE TO use one vote for me in every ROTM or ROTY thread! I know, I know... I don't make the rules though!

 

[Manwell]

Welcome @SikorskyGramps from both central and north GA!! Loved the Bussman detailed instruction link! I have one but have yet to do the install; I'm positive that will come is handy when I get to it!

 

[tjoreo]

Hi Guys,

First post here on the forum. I just picked up a 2017 1000-5 and have been reading everything I can get my hands on here. To say this forum is packed with an incredible amount of excellent information and knowledgable people would be a massive understatement. My first mod will be the dual battery setup and a Cooper Bussman power distribution panel. I got lucky and stumbled across an invaluable 6 part build guide for the Cooper Bussman from the ground up. Everything from part numbers to tools needed is listed. I'm going to tackle it myself and follow everything in the guide step by step. If it turns out half as clean as the finished product in this tutorial I'll be happy. The guy that put this thing together is an electrical artist has some serious skills..........

For anyone using the Cooper Bussman setup here's the link to the 6 part tutorial:

DIY Bussmann RTMR Fuse Block, Part 1 – Introduction | Bodenzord

Thats a good find and a very detailed write up. Just to pass this along, but many guys are picking up the unit off of ebay.

Universal Relay/ fuse auxiliary distribution box jeep, Cooper Bussmann Off Road

Either way enjoy that new ride when you pick her up.

 

[SikorskyGramps]

Thanks for the link tjoreo. That looks tempting for sure but I think I'd like to take a crack at it myself. I'd like to use an 80 amp resettable style breaker, 4 gauge wire for the battery hookups, 10 gauge for the relayed accessories plus solder everything as well on top of heat shrinking the ends of the mesh sheath. I really enjoy wiring projects plus it gives me an excuse to buy a few specialty tools I don't think you can beat that price though for a plug and play solution! I'm looking at around $600 to produce one with all the minimum parts purchase amounts, specialty tools and specialised waterproof plugs at each accessory Mind you, I'll have enough left overs afterwards to build another dozen minus the bare $28 Cooper Bussman fuse block and $9.99 Blue Sea negative bus bars. Maybe I can build up a few extras if the first one turns out well and recoup a few bucks on the initial outlay.

 

[tjoreo]

That sounds great to me and I love your ambition. I just didn't know if you saw this made up, so I thought I would pass it along. Keep us all posted.

 

[boatman22]

I just finished install the Bussman I got from ebay. Quality work.

 

[JTW]

Thanks for the link tjoreo. That looks tempting for sure but I think I'd like to take a crack at it myself. I'd like to use an 80 amp resettable style breaker, 4 gauge wire for the battery hookups, 10 gauge for the relayed accessories plus solder everything as well on top of heat shrinking the ends of the mesh sheath. I really enjoy wiring projects plus it gives me an excuse to buy a few specialty tools I don't think you can beat that price though for a plug and play solution! I'm looking at around $600 to produce one with all the minimum parts purchase amounts, specialty tools and specialised waterproof plugs at each accessory Mind you, I'll have enough left overs afterwards to build another dozen minus the bare $28 Cooper Bussman fuse block and $9.99 Blue Sea negative bus bars. Maybe I can build up a few extras if the first one turns out well and recoup a few bucks on the initial outlay.

I would have bought one from ya.. I would prefer mine a little heavier.. I tend to overdue things.

 

[SikorskyGramps]

I would have bought one from ya.. I would prefer mine a little heavier.. I tend to overdue things.

Thanks JTW It's strange why they ship the EBay package with a 60amp fuse when it's rated for 80 and only 12 gauge wire for the relay circuits when the relays are rated at 35a? I might be mistaken but I thought 12 gauge was for 20-25 amps only. I guess the big LED light bars don't draw much more than that anyways. I'm trying to find the draw on a small compressor like CumminsPusher recommended.......

 

[JTW]

Thanks JTW It's strange why they ship the EBay package with a 60amp fuse when it's rated for 80 and only 12 gauge wire for the relay circuits when the relays are rated at 35a? I might be mistaken but I thought 12 gauge was for 20-25 amps only. I guess the big LED light bars don't draw much more than that anyways. I'm trying to find the draw on a small compressor like CumminsPusher recommended.......

I bought mine from Amazon.. I'm sure it will be fine but I'm not going to over do it.. my 52" light bar will only draw around 25 amps and that's the heaviest draw I will have. I honestly don't understand the wire sizes but I just always make sure what I add and use is larger than that of the accessory, with the appropriate fuse in the system of course.

 

[AKRider]

Thanks JTW It's strange why they ship the EBay package with a 60amp fuse when it's rated for 80 and only 12 gauge wire for the relay circuits when the relays are rated at 35a? I might be mistaken but I thought 12 gauge was for 20-25 amps only. I guess the big LED light bars don't draw much more than that anyways. I'm trying to find the draw on a small compressor like CumminsPusher recommended.......

I think @CumminsPusher was probably referring to the type that plug into the accessory outlet. Something like this...

Amazon.com: Q Industries HV-35 SuperFlow 12-Volt 140 PSI Air Compressor: Automotive

Or even a smaller one, like the ones that come in the tire repair kits from Green Slime like this...

Amazon.com: Slime 40032 12-Volt Tire Inflator with Gauge and Light: Automotive

 

[CumminsPusher]

I think @CumminsPusher was probably referring to the type that plug into the accessory outlet. Something like this...

Amazon.com: Q Industries HV-35 SuperFlow 12-Volt 140 PSI Air Compressor: Automotive

Or even a smaller one, like the ones that come in the tire repair kits from Green Slime like this...

Amazon.com: Slime 40032 12-Volt Tire Inflator with Gauge and Light: Automotive

Sent from my iPhone using Tapatalk

 

[Smitty335]

Check Smitty 335

I've ordered the Trail Armor UHMW bottom. Do you recommend the matching A-Arm guards or aluminum? The CV boot coverage doesn't seem to be as good with the Trail Armor.

Yea I wish the trail Armor had a better front A arm design